Wheel Drive Shaft Inner Joint and Boot Replacement

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. 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 inboard boot (4) 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 the spacer rings (1) and (3) using J 8059 (or equivalent) to remove the spider assembly (2).





9. Remove the following items:
- The spacer ring (1)
- The spider assembly (2)
- The second spacer ring (3)
- The inboard boot (4)
10. Clean the halfshaft bar (5). Use a wire brush to remove any rust in the boot mounting area (grooves).
11. Inspect the following items on the spider assembly (2):
- The needle rollers
- The needle bearings
- The trunnion
12. Check the tripot housing for unusual wear, cracks, or other damage.
13. Replace any damaged parts.

Assembly Procedure

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





1. Place the new swage ring (2) onto the small end of the joint boot (1). Slide the joint boot (1) and the swage ring (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 41048 on the lower half of the J 41048.
3.4. Before proceeding, ensure there are no pinch points on the boot. This could cause damage to the 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 inboard boot (1)
- 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 (3) and spider assembly (2) onto the halfshaft bar (4) using J 8059.
6. Install the other spacer ring (1) using J 8059 in the groove at the end of the halfshaft bar. Ensure both rings are fully seated.





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

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





11. Slide the large diameter of the 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 boot must not be dimpled, stretched out or out of shape in any way. If the 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 boot properly by hand. Remove the tool.

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





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

14. Check the gap dimension on the clamp ear. If gap dimension is larger than shown, continue tightening until gap dimension is reached.