Wheel Drive Shaft Inner Joint and Boot Replacement

Wheel Drive Shaft Inner Joint and Boot Replacement

Special Tools

* J-35910 - Drive Axle Seal Clamp Pliers

* J-36652-1 - Drive Axle Clamp Swage Tool

* J-36652-98 - Axle Swage Tool

Disassemble Procedure

1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (1500) Wheel Drive Shaft ReplacementWheel Drive Shaft Replacement (2500/3500) Wheel Drive Shaft Replacement.





Note:
Use caution when removing the tripot housing (1).

2. Using the appropriate tool, remove the boot clamp (2).

3. Remove the tripot housing (1).

Note:
If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry.

4. Remove any grease from of the housing (1).





5. Using side cutters, remove the small boot retaining clamp (4).

6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3).





7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1).

8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly.

Assemble Procedure





1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3).





2. Install the small boot clamp (2) on the boot (1).





3. Using the J-35910 - pliers, a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures 2.15 mm (0.085 inch).





4. Install the spider assembly (2).

5. Using the appropriate tool, install the retaining ring (1).





Note:
Position the boot clamp so that it is at the small end of the boot.

6. Install the tripot assembly (1) and the boot clamp (2)





7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3).





Note:
Pinch the slightly by hand in order to distort it into an oval shape.

8. Install the boot (1) and the boot clamp (2) on the tripot housing (3).





9. For the 1500 models, assemble the bolts and the support plate to the base of the J-36652-98 - tool and secure the base in a vise.

10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J-36652-1 - tool and secure the base in a vise.





11. Position the tripot end of the wheel drive shaft assembly into the base of the J-36652-98 - tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models.

12. Install the top half of the J-36652-98 - Tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models.

13. Align the boot clamp (2) and the clamp.

Note:
Hand tighten the bolts until the bolts are snug.

14. Insert the bolts.

15. Align the tripot boot, tripot housing, and the boot clamp.

Note:
Alternate between the bolts until both sides of the top half of the tool touch the bottom half.

16. Tighten each bolt 180 degrees at a time.

17. Loosen the bolts and remove the halfshaft assembly from the tool.





18. Inspect the inboard stroke position.

* Measurement A for the 1500 models should be 170 mm (6 11/16 inch).

* Measurement A for the 2500, 3500, should be 178 mm (7 inch).

19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (1500) Wheel Drive Shaft ReplacementWheel Drive Shaft Replacement (2500/3500) Wheel Drive Shaft Replacement.