Rear Axle Shaft Disassembly/Assembly

Fig. 22 Exploded View Of Driveshaft:

Fig. 23 Snap Ring Removal & Installation:

DISASSEMBLY
1. Remove circlip from end of driveshaft.
2. Remove boot bands B and C, then the circlip and D.O.J. outer race.
3. Remove snap ring with suitable snap ring pliers as shown, then D.O.J. inner race, cage and balls as a unit.
CAUTION: Be careful that balls do not drop out of cage. If balls do drop out, press them back into D.O.J. cage with D.O.J. inner race.
4. Wipe any remaining grease off of driveshaft spline, then remove boot bands A and C.
5. Remove D.O.J. and B.J. boots.
NOTE: If boots are to be reused, wrap splined portion of driveshaft with vinyl tape before removing boots.
6. Remove dust cover, driveshaft and B.J.
NOTE: Do not disassemble B.J.

INSPECTION

1. Check driveshaft for damage, bending or corrosion.
2. Check driveshaft spline for wear or damage.
3. Check B.J. for entry of water or foreign material.
4. Check D.O.J outer race for damage or corrosion.
5. Check D.O.J. cage, balls and inner race for damage, corrosion or wear.

ASSEMBLY

1. Assemble driveshaft and B.J., then install dust cover.

Fig. 24 Driveshaft Boots Installation:

2. Wrap vinyl tape around driveshaft spline, then insert driveshaft in B.J. boot, boot bands A, C, C, B and D.O.J. boot in that sequence.
3. Fill inside of B.J. and B.J. boot with grease included in the driveshaft repair kit.
NOTE: The grease in the repair kit should be divided into two equal portions for the B.J. and B.J. boot. This is a special type of grease, ensure that no other type of grease comes in contact with the joint.
4. Secure B.J. boot with boot bands A and C to driveshaft and B.J.
NOTE: Ensure that B.J. is at a zero angle with driveshaft to ensure the boot contains the correct amount of air.

Fig. 25 Applying Grease To D.O.J. Cage, Balls & Inner Race:

5. Apply repair kit grease to D.O.J. cage, balls and inner race as shown.
6. Install cage, balls and inner race onto driveshaft, then using snap ring pliers, fit snap ring securely into groove in shaft.
7. Fill D.O.J. outer race with repair kit grease, then fit driveshaft into D.O.J. outer race.
8. Fill more grease into D.O.J. outer race after it is installed on driveshaft, then install circlip onto D.O.J. outer race.
9. Assemble D.O.J. boot to D.O.J. outer race, then secure boot to driveshaft with boot band C.
10. Place boot band B on D.O.J. boot.
NOTE: Do not secure boot band B at this time.

Fig. 26 Driveshaft Boot Bands Installation:

11. Set D.O.J. boot bands from 2-3/4 to 3-1/4 inches apart as shown then tighten boot band C securely.
12. Pull part of D.O.J. boot away from D.O.J. outer race to allow pressure to escape from boot, then tighten boot band B securely to D.O.J. outer race.