Wheel Drive Shaft Inner Joint and Seal Replacement
FRONT DRIVE AXLE- DRIVE SHAFT INNER JOINT AND SEALDisassembly Procedure
^ Tools Required
- J 8059 Snap Ring Pliers
Notice: Do not damage the tripot housing (1).
Important: With removal of the halfshaft for any reason, the transmission sealing surface (the tripot male/female shank of the halfshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the halfshaft reinstalled free of any buildup.
1. Use a hand grinder in order to cut through the swage ring (2).
2. Remove the tripot housing (1) from the halfshaft.
3. Wipe the grease off of the tripot assembly roller bearings and the tripot housing (1).
4. Thoroughly degrease the tripot housing (1).
5. Allow the tripot housing (1) to dry prior to assembly.
Important: Handle the tripot spider assembly with care. Tripot balls and needle rollers may separate from the spider trunnion if the tripot balls and needle rollers are not handled carefully.
Use side cutters to cut away the small boot clamp.
6. Compress the tripot boot (2) up the halfshaft (4), away from the tripot spider assembly (1) toward the outboard (CV joint assembly) end of the halfshaft (1).
7. Spread the spider spacer ring (2) with J 8059 (or equivalent).
8. Remove the following items from the halfshaft bar:
8.1. The spacer ring (1)
8.2. The spider assembly (2)
8.3. The tripot boot (3)
9. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
10. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts.
Assembly Procedure
^ Tools Required
- J 35910 Seal Clamp Tool
- J 36652-98 Split Plate Swage Clamp (K1 5 models)
- J 36652-1 Split Plate Swage Clamp (K25 models)
1. Place the new small boot clamp (2) onto the small end of the joint boot (1). Compress the joint boot (1) and small boot clamp (2) onto the halfshaft bar.
2. Position the small end of the joint boot (1) into the joint boot groove (3) on the halfshaft bar.
Notice: Refer to Fastener Notice in Service Precautions.
3. Secure the small boot clamp (1) with J 35910 (or equivalent), a breaker bar, and a torque wrench.
Tighten the small boot clamp (1) to 136 Nm (100 ft. lbs.).
4. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
Important: Assemble the CV joint with the convolute retainer in the correct position, as illustrated.
5. Install the convolute retainer over the inboard joint boot, being sure to capture three convolutions.
6. Install the tripot spider assembly (3) onto the halfshaft bar (2) with the counterbore towards the end of the halfshaft bar (2).
7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2).
8. Push the spider assembly (1) back toward the end of the halfshaft bar (2) until the spacer ring is covered by the spider assembly (1) counterbore.
9. Pack the tripot boot (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
10. Reassemble the tripot housing and the tripot boot using the following procedure:
10.1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape.
10.2. Slide the distorted swage ring (2) over the large diameter of the boot.
10.3. Place the tripot housing over the spider assembly.
10.4. Install the boot onto the tripot housing.
10.5. Align the tripot boot (1), with the swage ring (2) in place, over the flat area on the tripot housing (3).
11. Mount J 36652 in a vise.
12. Install the bottom half of the split-plate swage clamp. For K1 5 models, use J 36652 -98.
13. For K25 models, use J 36652 -1.
14. Check the inboard stroke position.
^ Use measurement A for the K15 models.
^ Use measurement B for the K25 models.
15. Position the inboard end (tripot end) of the halfshaft assembly in J 36652.
16. Install the top half of the proper size tool on the lower half of the tool. For K15 models, use J 36652 -98.
17. For K25models, use J 36652 -1.
18. Align the swage ring (2) and the swage ring clamp.
19. Insert the bolts.
Hand tighten the bolts in J 36652 until the bolts are snug.
Important: Align the following during this procedure:
^ The tripot boot (3)
^ The housing (1)
^ The swage ring (2)
Tighten
Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of the J 36652.
20. Loosen the bolts and remove the halfshaft assembly from J 36652.
21. Remove the convolute retainer from the boot.