Wheel Drive Shaft Inner Joint and Seal Replacement

Wheel Drive Shaft Inner Joint and Seal Replacement
^ Tools Required
- J 8059 Snap Ring Pliers
- J 35910 Seal Clamp Tool
- J 36652 Split Plate Swage Clamp

Disassembly Procedure





Notice: With the removal of the wheel drive shaft for any reason, the transmission sealing surface (the tripot male/female shank of the joint) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotational motion only. Do not clean with an oscillating motion. Transmission fluid may be used to clean off any remaining debris and the joint wiped dry before installation. Corrosion on the joint sealing surface may damage the transmission seals and cause a fluid leak.

Important: Use caution when using the hand grinder by the tripot housing (1).

1. Use a hand grinder in order to cut through the swage ring (2).
2. Remove the tripot housing (1) from the halfshaft.
3. Wipe the grease off of the tripot assembly roller bearings and the tripot housing (1).
4. Thoroughly degrease the tripot housing (1).
5. Allow the tripot housing (1) to dry prior to assembly.





Important: Handle the tripot spider assembly with care. Tripot balls and needle rollers may separate from the spider trunnion if the tripot balls and needle rollers are not handled carefully.
Use side cutters to cut away the small seal clamp.

6. Compress the tripot seal up the halfshaft, away from the tripot spider assembly toward the outboard (CV joint assembly) end of the halfshaft.
7. Spread the spider spacer ring (2) with J 8059 (or equivalent).





8. Remove the following items from the halfshaft bar:
8.1. The spacer ring (1)
8.2. The spider assembly (2)
8.3. The tripot seal (3)
9. Clean the halfshaft bar (4). Use a wire brush in order to remove any rust in the seal mounting area (grooves).
10. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate service kit.

Assembly Procedure





1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.





Notice: Refer to Fastener Notice in Service Precautions.

3. Secure the small seal clamp (1) with J 35910 (or equivalent), a breaker bar, and a torque wrench.
^ Tighten the small seal clamp (1) to 136 Nm (100 ft. lbs.).
4. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.





Important: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated.

5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions:
^ 2-5 for the K1500 model.
^ 2-4 for the K2500, K3500, and Hummer 2 models.





6. Install the tripot spider assembly (3) onto the halfshaft bar (2).
7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2).





8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.





9. Reassemble the tripot housing and the tripot seal using the following procedure:
9.1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape.
9.2. Slide the distorted swage ring (2) over the large diameter of the seal.
9.3. Place the tripot housing over the spider assembly.
9.4. Install the seal onto the tripot housing.
9.5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3).





10. Mount the base of J 36652 in a vise.





11. Check the inboard stroke position.
^ Use measurement A for the K1500 models.
^ Use measurement B for the K2500, K3500, and Hummer 2 models.





12. Position the inboard end (tripot end) of the halfshaft assembly into the base of J 36652.
13. Install the top half of J 36652.
14. Align the swage ring (2) and the swage ring clamp.
15. Insert the bolts.
^ Hand tighten the bolts in J 36652 until the bolts are snug.

Important: Align the following during this procedure:
^ The tripot seal (3)
^ The housing (1)
^ The swage ring (2)

^ Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of J 36652.
16. Loosen the bolts and remove the halfshaft assembly from J 36652.





17. Remove the convolute retainer tool from the seal.