Disassembly and Assembly

The following abbreviations are used in this section, D.O.J. for double offset joint and C.V.J. for constant velocity joint.

DISASSEMBLY

1. Refer to ``Axle Shaft, Replace'' procedure and remove axle from vehicle.
2. Straighten bent claw of large end of boot on D.O.J. side of axle shaft, then loosen boot band.
3. Remove boot band on small end of D.O.J. side in same manner, then slide boot away from joint.
4. Remove round circlip at neck of outer race on D.O.J. side with screwdriver.
5. Remove outer race on D.O.J. side from shaft assembly.
6. Remove balls and move cage to boot side, then turn cage by 1/2 pitch to track groove of inner race and remove snap ring, inner race, cage and boot. The C.V.J. is not to be disassembled.

INSPECTION

1. Check D.O.J. and C.V.J. for seizure, corrosion, damage, or excessive wear.
2. Check shaft for bending, twisting, damage and wear.
3. Check boot for wear, warping aacking.

ASSEMBLY

1. Install boot on C.V.J. side and fill with 2-2.5 oz. of special constant velocity joint grease Molylex No. 2 or equivalent.
2. Position boot from D.O.J. side at center of shaft, then insert cage of D.O.J. with recess facing outward.
3. Install inner race of D.O.J. onto shaft and secure with snap ring.
4. Install cage, which was previously positioned, with protruding part aligned with track on inner race and then turn by 1/2 pitch. Apply 0.75-1 oz. of special grease to cage pocket and insert 6 balls into cage pocket, then fill interior of outer race with .75-1 oz. of special grease.
5. Align outer race track and ball positions, then fit outer race to inner race and cage.
6. Install circlip into groove on outer race of D.O.J., then pull shaft to ensure circlip is seated in groove.
7. Apply .75-1 oz. of grease to interior of D.O.J. and shaft area, then fill boot with .75-1 oz. of grease and install. When installing boot, position outer race of D.O.J. at center of its travel.
8. Install new boot bands using suitable tool and tighten until it cannot be moved by hand. While tightening band, be sure there is enough air within boot.
9. Tap on clip of band with suitable punch at end of tightening tool and cut off excess band at about .4 inch (10 mm) from clip, then bend band over clip.
10. Fill C.V.J. boot and C.V.J. with special grease and install in same manner as D.O.J. boot.