Disassembly and Assembly, Rear Drive Halfshafts

Halfshaft Joint





Special Tool(s)

Disassembly
1. Remove the halfshaft assembly from the vehicle.





2. For the inboard CV joint. carry out the following:
1 Remove and discard the boot clamps.
2 Remove the inboard CV joint housing.





3. NOTE: Install the halfshaft in a soft jaw vise.

For the inboard CV joint, carry out the following:
1 Remove and discard the retainer circlip.
2 Slide the boot away from the CV joint.





4. Using a suitable Claw puller, remove the CV joint.





5. Remove and discard the tri-lobe insert and the boot.





6. NOTE: The outboard CV joint is not removable from the halfshaft. The boot must be removed or installed from the inboard CV joint side of the shaft.

For the outboard CV joint, carry out the following:
1 Remove and discard the boot clamps.
2 Remove and discard the boot.
7. Inspect the grease, packed in the inboard CV joint and the outboard CV joint, for contamination. Rub some of the grease from each joint between two fingers. Any gritty feeling indicates contamination. Wash all of the grease from the inboard CV joint, the inboard CV joint housing, the outboard CV joint, and the interconnecting shaft. Thoroughly dry all of the components and inspect them for wear or damage. Discard the assembly, if necessary. Only proceed as follows if not discarding the assembly.





8. If necessary, remove and discard the outboard dust seal.
^ Tap uniformly around the seal to separate it from the joint.





9. If necessary, remove and discard the inboard dust seal.
^ Tap uniformly around the seal to separate it from the housing.





10. On the inboard end, remove and discard the retainer circlip.

Assembly





1. NOTE: Clean any excess grease from the boot mounting surfaces before installing the boot.

For the outboard CV joint, carry out the following:
1 Slide the boot on the interconnecting shaft.
2 Pack the outboard CV joint with 275 grams (9.7 ounces) of grease.
3 Spread any remaining grease evenly inside the boot.
4 Install the boot by seating it in the groove in the CV joint housing.





2. NOTE: Tighten the through-bolt until the special tool is in the closed position.

Using the special tool, install both boot clamps.





3. If removed, use the special tools to install the dust seal.





4. NOTE: Install the halfshaft in a soft jaw vise.

NOTE: The lip on the end of the tri-lobe insert must seat against the end of the boot.

For the inboard CV joint, carry out the following:
1 Position the clamp on the interconnecting shaft.
2 Position the boot on the interconnecting shaft.
3 Install the tri-lobe insert.





5. NOTE: One side of the inboard CV joint has a chamfer cut in the edge of joint at the inner diameter near the splines. Install the inboard CV joint so that the chamfer faces the outboard end of the halfshaft.

Install the CV joint.





6. Install the retainer circlip.





7. NOTE: Clean any excess grease from the boot mounting surfaces before installing the boot.

For the inboard CV joint, carry out the following:
1 Pack the inboard CV joint housing with 325 grams (11.5 ounces) of grease.
2 Spread any remaining grease evenly inside the boot and on the CV joint.
3 Install the inboard CV joint housing, seating the boot in the groove in the housing.





8. Set the halfshaft assembled length to specification.
1 Measure the entire assembly length.
2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length to specification.
3 Hold the inner joint to prevent the assembled length from changing, and insert a small flat blade screwdriver between the boot and the joint to equalize the pressure.





9. NOTE: Tighten the through-bolt until the special tool is in the closed position.

Using the special tool, install both boot clamps.





10. If removed, use the special tools to install the dust seal.





11. CAUTION: Do not over expand or twist the circlip during installation.

Install a new retainer circlip.
12. Install the halfshaft assembly in the vehicle.