Inner Joint and Boot Replacement (Inboard Assembly)

Disassembly Procedure

- Tools Required
+ J 8059 Snap Ring Pliers

Notice: With removal of the halfshaft for any reason, the transmission sealing surface (the tripot male/female shank of the halfshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotational motion. Do not clean with in oscillating motion. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the halfshaft reinstalled free of any buildup.





1. Use a hand grinder in order to cut through the swage ring. Do not damage the tripot housing (1).
2. Remove the large boot retaining clamp from the tripot joint with side cutter.
3. Dispose of the large boot retaining clamp.

Notice: Do not cut through the halfshaft inboard boot and damage sealing surface of the outer housing and the trilobal tripot bushing.

4. Separate the halfshaft inboard boot from the trilobal tripot bushing (3) at the large diameter.
5. Slide the boot (4) away from the joint along the halfshaft bar.
6. Remove the housing (1) from the tripot joint spider (2) and the halfshaft bar.
7. Remove the trilobal tripot bushing (3) from the housing (1).
8. Spread spacer ring (2) with J 8059.





9. Slide the spacer ring and tripot joint spider back on halfshaft bar (1).





10. Remove the halfshaft bar retaining ring from the groove (5) on the halfshaft bar.
11. Slide tripot joint spider assembly (2) off of the halfshaft bar.
12. Clean the following items with cleaning solvent:
- The tripot balls
- The needle rollers
- The housing
13. Remove all traces of old grease and any contaminates. Dry all parts.





14. Inspect the following parts for damage or wear:
- The halfshaft inboard boot (4)
- The tripot joint spider assembly (2)
- The housing (1)
- The trilobal tripot bushing (3)
- The needle rollers

Assembly Procedure

- Tools Required
+ J 35910 Earred Clamp Tool
+ J 41048 Small Swage Tool





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





3. Mount J 41048 in a vise and proceed as follows:
3.1. Position the outboard end (1) of the halfshaft assembly in tool J 41048.
3.2. Align the top of boot neck on the bottom die using the indicator.
3.3. Place the top half of the J 410480 on the lower half of the J 41048.
3.4. Before proceeding, ensure there are no pinch points on the halfshaft inboard boot. This could cause damage to the halfshaft inboard boot.
3.5. Insert the bolts (2).
3.6. Tighten the bolts by hand until snug.

Notice: Refer to Fastener Notice in Service Precautions.





4. Align the following items:
- The halfshaft inboard boot (1)
- The housing
- The swage ring (2)
^ Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.





5. Install the spacer ring (2) on the halfshaft bar (1) in groove using J 8059.

Important: Ensure that the counterbored face of the tripot joint spider (2) faces toward the end of the halfshaft bar (4).





6. Slide the tripot joint spider assembly (2) toward the spacer ring (1) as far as it will go on the halfshaft bar (4).
7. Install the halfshaft bar retaining ring in the groove of the halfshaft bar.

Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).





8. Place approximately half of the grease from the service kit in the halfshaft inboard boot. Use the remainder of the grease to repack the housing.
9. Install the trilobal tripot bushing (3) to housing.
10. Position the larger new boot retaining clamp (2) on the halfshaft inboard boot.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.





12. Slide the large diameter of the halfshaft inboard boot (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.

Important: The halfshaft inboard boot must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard boot is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing in order to equalize the pressure. Shape the halfshaft inboard boot properly by hand. Remove the tool.

13. Position the joint assembly at the proper vehicle dimension.





14. Align the following items while latching:
- The halfshaft inboard boot (3)
- The tripot housing (1)
- The large boot retaining clamp (2) Tighten Crimp the boot retaining clamp (2) with J 35910 to 176 Nm (130 ft. lbs.). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary.