Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement REMOVAL PROCEDURE Tools Required - J 8059 Snap Ring Pliers - J 35910 Seal Clamp Tool - J 41048 Small Swage Tool 1. Remove the large seal retaining clamp from the C/V joint with a side cutter. Discard the seal retaining clamp. NOTICE: Take care when using the hand grinder to avoid damage to the axle shaft. 2. Use a hand grinder to cut through the swage ring in order to remove the swage ring. 3. Separate drive axle outboard seal from C/V joint outer race (1) at large diameter. 4. Slide the seal (5) away from joint along axle shaft (4). 5. Wipe the grease from the face of the C/V Joint inner race (2). 6. Spread the ears on the race retaining ring (3) with J 8059. 7. Remove the C/V joint assembly (1) from the axle shaft (4). 8. Remove the drive axle outboard seal (5) from the axle shaft (4). 9. Discard the old outboard seal.
10. Place a brass drift against the C/V joint cage (1). 11. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 12. Remove the first chrome alloy ball (2) when the C/V joint cage (1) tilts. 13. Tilt the C/V joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 14. Repeat this process to remove all six of the balls. 15. the lands of the outer race (2). 16. Lift out the cage (4) and the inner race. 17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 18. Clean the inner and outer race assemblies, the C/V joint cage and the chrome alloy balls thoroughly with cleaning solvent. remove all traces of old grease and any contaminates. 19. Dry all the parts. 20. Check the C/V joint assembly for unusual wear, cracks, or other damage. 21. Replace any damaged parts. 22. Clean the axle shaft. Use a wire brush to remove any rust in the seal mounting area (grooves). INSTALLATION PROCEDURE
Tools Required - J 35910 Earless Seal Clamp Tool - J 41048 Small Swage Tool Inspect all of the parts for unusual wear, cracks, or other damage. Replace the Joint assembly if necessary. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Insert the inner race (1) into the cage (2) by rotating the inner race (1) downward: 1. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 2. Align the lands of the inner race (1) with the windows of the cage (2). 3. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. Insert the cage (4) and inner race into the outer race (1). Place a brass drift against the C/V Joint cage (1). Tap gently on the brass drift with a hammer in order to tilt the cage (1). Install the first chrome alloy ball (2) when the C/V joint cage (1) tilts. Tilt the C/V joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2).
Repeat this process to install all six of the balls. Pack the C/V joint seal (1) with half of the grease supplied in the service kit. The amount of grease supplied in this kit has been pre-measured for this application. Pack the C/V joint with the remaining grease. Push the C/V joint onto the axle shaft until the retaining ring is seated in the groove on the axle shaft. Install the new swage ring on the neck of the drive axle outboard seal. Do not swage. Slide the drive axle outboard seal (1) onto the axle shaft and position the neck of the drive axle outboard seal in the seal groove (3) on the axle shaft. (3) and locate the seal lip in the groove on the C/V joint outer race.
Mount J 41048 in a vise and proceed as follows: 1. Position the outboard end (1) of the halfshaft assembly in J 41048. 2. Align the top of the seal neck on the bottom die using the indicator line. 3. Place the top half of J 41048 on the lower half of J 41048. 4. Make sure there are no pinch points on the drive axle outboard seal before proceeding. This could cause damage to the drive axle outboard seal. 5. Insert the bolts (2). 6. Tighten the bolts (2) by hand until snug. Align the following: - the drive axle outboard seal (1) - the outer race - the swage ring (2) - Tighten each bolt 180 degrees at a time, using a ratchet wrench. Alternate between each bolts until both sides are bottomed. IMPORTANT: The drive axle outboard seal must not be dimpled, stretched or out of shape in any way. In order to correct the shape of the drive axle outboard seal:
1. Carefully insert a thin flat blunt tool without sharp edges into the large seal (3) opening to equalize the pressure. 2. Shape the seal properly by hand. 3. Remove the tool. Secure the small seal clamp (6) with J 35910 (or equivalent), a breaker bar (5), and a torque wrench (4). Tighten the small seal retaining clamp (2) to 174 Nm (130 ft. lbs.). Check the gap dimension on the clamp ear.