Rear Wheel Drive Shaft Outer Joint and Boot Replacement

Rear Wheel Drive Shaft Outer Joint and Boot Replacement


Tools Required
* J 35566 Drive Axle Seal Clamp Pliers
* J 42572 Drive Shaft Seal Clamp Pliers



Disassembly Procedure





1. Remove the small seal clamp from the wheel drive shaft bar using side cutters and discard the clamp.

Important: Do not cut into the wheel drive shaft trilobal tripot bushing.


2. Remove the large seal clamp (4) from the tripot joint with side cutters and discard the clamp.
3. Separate the wheel drive shaft outboard seal from the trilobal tripot bushing (5).
4. Slide the seal away from the joint along the wheel drive shaft bar.
5. Remove the housing from the tripot joint spider and the wheel drive shaft bar.

Important: The correct 60 degree offset relationship between the inner and outer tripot spiders must be maintained. Accurately reference mark the tripot spider position on the wheel drive shaft bar before disassembly.






6. Reference mark the position of the tripot spider (1) on the wheel drive shaft bar (2).
7. Using a brass drift and hammer, carefully tap around the tripot spider face in order to compress the barrel retaining ring on the wheel drive shaft bar.
8. Remove the tripot spider from the wheel drive shaft bar (2).
9. Remove and discard the barrel retaining ring from the wheel drive shaft bar.
10. Remove the joint seal from the wheel drive shaft bar.
11. Inspect the following parts for damage or wear:

* The wheel drive shaft outboard seal
* The tripot joint spider assembly (1)
* The housing
* The trilobal tripot bushing




Assembly Procedure





1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the small seal clamp (2) onto the wheel drive shaft bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the wheel drive shaft bar.

Notice: Refer to Fastener Notice .

3. Using the J 42572 , crimp the small seal retaining clamp.

Tighten the clamp to 136 N.m (100 lb ft).





4. Install a new barrel retaining ring to the wheel drive shaft bar.

Important: The proper 60 degree offset relationship between the inner and outer tripot spiders must be maintained.


5. Align the reference mark on the tripot spider and the wheel drive shaft bar.

Important: Ensure that the beveled edge of the tripot spider faces the wheel drive shaft bar during reassembly.


6. Install the tripot spider to the wheel drive shaft bar, while compressing the barrel retaining ring with a flat-bladed tool.
7. Verify positive engagement of the tripot spider to the wheel drive shaft bar by grasping the tripot spider and attempting to pull free from the wheel drive shaft bar.





Important: Ensure the trilobal tripot bushing is flush with the face of the housing.


8. Place approximately half of the grease from the service kit in the wheel drive shaft outboard seal. Use the remainder of the grease to repack the housing.
9. Install the trilobal tripot bushing (5) to the housing (1).
10. Install the spring (2) to the tripot housing.
Use grease from the housing in order to retain the spring.
11. Install the guide (3) to the spring.
Use grease from the housing in order to retain the guide.
12. Position the larger new seal retaining clamp (4) on the wheel drive shaft outboard seal.
13. Slide the housing over the tripot joint spider assembly on the wheel drive shaft bar.




14. Slide the large diameter of the wheel drive shaft outboard seal (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.

Important: The seal must not be dimpled, stretched or otherwise deformed.


15. Inspect the seal for proper shape.
If the seal is not shaped correctly, equalize the pressure in the seal by lifting the seal edge slightly and shape the seal properly by hand.
16. Position the joint assembly at the proper vehicle dimension.




17. Align the following items while latching:

* The wheel drive shaft outboard seal (1)
* The tripot housing
* The large seal retaining clamp (2)

18. Using the J 35566 , latch the large seal retaining clamp. Ensure that the latching tangs are fully engaged in the large seal clamp band.
19. Rotate the outer tripot housing four or five times in order to distribute the grease throughout the tripot spider bearings.