Disassemble and Assemble

Fig. 11 Deflector Ring Removal From Axle.:

Fig. 12 Outer CV Joint Retaining Clamp Removal.:

Fig. 13 Race Retaining Ring.:

Fig. 14 CV Joint Ball Removal.:

Fig. 15 Tri-pot Housing Separation From Spider & Shaft.:

Fig. 16 Spider Assembly Retaining Ring Removal From Shaft.:

DISASSEMBLY
1. Clamp axle shaft in a vise.
2. If drive axle has a damaged deflector ring, remove ring from CV outer race using a brass drift and hammer and discard, Fig. 11 .
3. Remove outer CV joint and seal as follows:

a. Cut seal retaining clamps on CV joint seal with side cutters or a flat screw driver. Disengage outer band from inner band at retainer peg and discard clamp, Fig. 12 .
b. Separate joint seal from CV joint race at large diameter and slide seal along axle shaft away from joint.
c. Wipe excess grease from face of CV inner race.
d. Spread ears on race retaining ring with snap ring pliers No. SA9198C, or equivalent, and remove CV joint assembly from axle shaft, Fig. 13.
e. Remove axle seal from shaft.
4. Disassemble CV joint as follows:

a. Using a brass drift, gently tap on cage until tilted enough to remove first ball, Fig. 14. Remove remaining balls in similar manner.
b. With all balls removed, pivot cage and inner race 90 degrees to center line of outer race with cage windows aligned with lands of outer race, then lift out cage and inner race.
c. Rotate inner race up and out of cage.
d. Thoroughly clean all CV joint parts and allow to dry.
5. Remove tri-pot joint and seal as follows:

a. Cut eared seal retaining clamp on tri-pot seal using side cutters and discard.
b. Remove and discard clamp using a small bladed screwdriver.
c. Separate seal from tri-pot housing at large diameter and slide seal along axle shaft away from joint.
d. Wipe excess grease from face of tri-pot spider and inside of tri-pot housing, then remove tri-pot housing from spider and shaft, Fig. 15 .
e. Spread spacer ring with snap ring tool No. SA9198C, or equivalent, and slide spacer ring and tri-pot spider back on axle, Fig. 16 .
f. Remove spider retaining ring from groove on axle shaft and slide spider assembly off shaft. Handle tri-pot spider assembly with care. Tri-pot balls and needle rollers mat separate from spider trunnions.
g. Remove seal from axle shaft, then thoroughly degrease housing and allow to dry.

Fig. 17 Small CV Joint Retaining Clamp Crimp.:

Fig. 18 Large CV Joint Retaining Clamp Crimp.:

Fig. 19 Deflector Ring Installation.:

Fig. 20 Small Tri-pot Seal Retaining Ring Crimp.:

Fig. 21 Tri-pot Assembly At Proper Vehicle Dimension.:

Fig. 22 Tri-pot Large Retaining Clamp Installation.:

ASSEMBLY
1. Assembly CV joint as follows:

a. Inspect parts for unusual wear, cracks and other damage. Replace joint assembly if needed.
b. Place a light coat of grease on all inner and outer race grooves, then insert and rotate inner race into cage.
c. Install cage and inner race into outer race with windows of cage aligned with lines of outer race.
d. Install balls using a brass drift to gently rotate and position cage and inner race.
e. Pack assembled joint with grease provided with service kit.
2. Install outer CV joint and seal as follows:

a. Install small retaining clamp on neck of new seal. Do not crimp.
b. Slide seal onto axle shaft and locate neck of seal in proper position in seal if groove on axle shaft.
c. Crimp seal retaining clamp with tool No. SA9203C, or equivalent, Fig. 17. Check clamp location during crimp operation to ensure it is positioned correctly around entire circumference.
d. Measure clamp ear end gap dimension and recrimp if necessary.
e. Place approximately half of grease provided in kit, inside seal and pack CV with remaining grease.
f. Position large seal retaining clamp around seal. Ensure retaining ring side of inner race faces axle prior to installation.
g. Push CV joint onto axle shaft until retaining ring is seated in groove on axle shaft.
h Slide large diameter of seal over outside of CV joint race and locate lip of seal in housing groove.
i. Crimp seal retaining clamp with tool No. SA9203C, or equivalent, Fig. 18 . Check clamp location during crimp operation to ensure it is positioned correctly around entire circumference.
j. Measure clamp ear end gap dimension and recrimp if necessary.
k. Position deflecting ring at CV joint outer race, if removed.
l. Using tool No. SA9160C, or equivalent, and a M20 x 1.0 nut, tighten nut until deflector bottoms against shoulder of CV outer race, Fig. 19 .
3 Install tri-pot joint and seal as follows:

a. Inspect tri-pot joint components for unusual wear, cracks and other damage and replace if needed.
b. Clean shaft. If rust is present in seal mounting area, remove rust with wire brush.
c. Install small seal retaining clamp on neck of seal. Do not crimp.
d. Slide seal onto shaft and locate neck of seal in proper position in seal groove on axle shaft.
e. Crimp seal retaining clamp with tool No. SA9203C, or equivalent, Fig. 20 . Check clamp location during crimp operation to ensure it is positioned correctly around entire circumference.
f. Measure clamp ear end gap dimension and recrimp if necessary, then install spacer ring on axle shaft and beyond second groove.
g. Slide tri-pot spider assembly past spider retaining ring groove. Ensure counterbored surface of tri-pot spider faces end of shaft after installation.
h. Install spider retaining ring in groove of axle shaft with snap ring tool No. SA9198C, or equivalent, then slide tri-pot spider towards end of shaft and reseat spacer ring in groove on axle.
i. Place approximately half of the grease provided in kit in side seal and use the remainder to pack tri-pot housing.
j. Install new convolute retainer over seal. Joint must be assembled with convolute retainer in position . Seal damage will result if joint is not assembled to correct dimension.
k. Position seal retaining clamp around large diameter of seal, then slide tri-pot housing over tri-pot spider assembly on shaft.
l. Slide large diameter of seal over outside of tri-pot housing and locate lip of seal in housing groove.
m. Position tri-pot assembly at proper vehicle dimension, Fig. 21 .
n. Place large seal retaining clamp around seal and close with tool No. SA9161C, or equivalent, Fig. 22 .