Outer CV Joint Replacement

OUTER CV JOINT/BOOT REPLACEMENT

TOOL REQUIRED:
* J 8059 Snap Ring Pliers (or equivalent) J 35910 Boot Clamp Tool
* Place the drive axle in a vise using a protective covering on the vise jaws.

DISASSEMBLE
* Install seal clamp protectors.
1. Clamps.
A. Cut the clamps from the seal using a pair of side cutters.
B. For swedge ring removal, use a hand grinder to cut through the ring, taking care not to damage the outer race.
C. Slide the boot down the shaft away from the CV joint outer race.
D. Wipe the grease away from the face of the CV joint revealing the snap ring.






2. Snap ring using J 8059.
3. Joint assembly from the axle shaft.
* Discard the boot.

CLEAN
* Thoroughly degrease the outer joint assembly and allow to dry before reassembly.

INSPECT
* Outer joint assembly for unusual wear, cracks and other damage. Replace as necessary.

CLEAN
* The shaft. If rust is present in the seal mounting area (grooves), wire brush this area.






4. Balls.
* Using a brass drift and hammer, tap on the cage until it tilts enough to remove the first ball. Remove the other balls in the same manner.

5. Cage from the outer race.
A. Pivot the cage with inner race 90 degrees to the centerline of the outer race.





B. Align the (1) cage windows with the (2) lands of the outer race.
C. Lift out the cage with the inner race.






6. Inner race. Rotate (3) inner race 90 degrees to center line of cage with (1) lands of inner race aligned with (2) windows of cage.

CLEAN
* Parts in an approved solvent.

ASSEMBLE

TOOLS REQUIRED:
* J 8059 Snap Ring Pliers (or equivalent) J 35910 Clamp Installer
* Apply grease to the ball grooves of the inner race, and outer race.






1. Inner race to the cage.






A. Rotate into place, as shown. Cage with inner race to the outer race.
B. Align the cage windows with the lands. Pivot the cage into position.
C. Make sure the retaining ring side of the inner race faces out.






2. Balls.
A. Tap on the cage with a brass drift to tilt it enough to install the balls.
B. Pack the joint with grease.
3. Small boot clamp onto outboard boot.
4. Outboard boot to the axle shaft.






TIGHTEN
* Tighten small clamp using J 35910 to 136 Nm (100 lbs. ft.).

MEASURE
* Clamp ear gap dimension.

5. Joint assembly to the axle shaft.
6. Snap ring.
A. Pack the boot and outer joint assembly with premeasured amount of grease supplied in the service kit.
B. Snap the boot onto the outer joint assembly then manipulate the joint and boot to remove excess air.






7. Large clamp using J 35910.

TIGHTEN
* Large clamp to 176 Nm (130 lbs. ft.)

MEASURE
* Clamp ear gap dimension.