Inner Joint and Boot Replacement (Tripot Joint)

Disassembly Procedure

^ Tools Required
J 8039-A Snap Ring Pliers

Important: Do not cut through boot and damage sealing surface of outer housing (1) or tri-lobal tripot bushing (2).





1. Remove the small boot retaining clamp from the halfshaft bar (3) with a side cutter. Discard the small boot retaining clamp.
2. Remove the large boot retaining clamp from the inboard joint with a side cutter. Discard the large boot retaining clamp.
3. Separate the inboard boot from the trilobal tripot bushing (2) at large diameter.
4. Slide boot away from joint along halfshaft bar (3).
5. Before removing the tripot spider assembly (3) from the halfshaft bar, perform the following procedure:

Important: Never reuse the spacer ring (2).





6. Remove the spacer ring (2) from the end of the halfshaft bar using J 8039-A.





7. Place a brass drift on the area of the tripot spider (1 ) next to the halfshaft bar (3).
8. Tap on the brass drift with the hammer.

Important: Handle the tripot spider assembly (1) with care.

9. Remove the tripot spider assembly (1) from the halfshaft bar (3).





10. Remove the spacer ring (1) from the shoulder of the halfshaft bar using J 8039-A.
11. Remove the trilobal tripot bushing from the housing.
12. Clean the following items thoroughly with cleaning solvent. Removing all traces of old grease and any contaminates.
^ The tripot balls
^ The needle rollers
^ The housing
13. Dry all the parts.
14. Remove the boot from the halfshaft bar.
15. Inspect the following parts for damage or wear:
^ The inboard boot
^ The spider assembly (3)
^ The housing
^ The trilobal tripot bushing
^ The tripot balls
^ The needle rollers
^ The retaining ring (1)

Assembly Procedure

^ Tools Required
^ J 35910 Seal Clamp Tool
^ J 35566 Earless Seal Clamp Tool

1. Install the new small boot retaining clamp on the neck of the boot.
2. Do not crimp the small boot retaining clamp.
3. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves).
4. Slide the tripot boot onto the halfshaft bar, passing the boot grooves of the halfshaft bar toward the CV end of the halfshaft bar.





Important: Ensure that the spacer ring (1) is next to the shoulder of the halfshaft bar before installing the tripot spider (3).

5. Place the new spacer ring (1) next to the shoulder on the halfshaft bar.





6. Place the tripot spider assembly (3) onto the halfshaft bar.
7. Place the halfshaft assembly onto the arbor press.
^ The tripot spider assembly must be on the press plate.
^ The CV joint assembly must be under the press head.
8. Lower the arbor press head onto the CV joint assembly until the tripot spider is next to the spacer ring. Do not exceed 4,000 lbs. press load during assembly.
9. Remove the halfshaft assembly from the arbor press.





10. Place the new spacer ring (2) on the halfshaft bar groove at the end of the halfshaft bar.





11. Slide the tripot boot (7) the corresponding groove on the halfshaft bar.
12. Crimp the small boot retaining clamp (6) using J 35910.
13. Place approximately of the grease from the service kit in boot. Use the remainder to repack the housing.





14. Install trilobal tripot bushing (2) to housing (1). Ensure the bushing (2) is flush with the face of the housing (1).
15. Slide the housing (1) over the spider assembly on the halfshaft bar (3).

Important: The end of the inboard boot (4) must be next to the boot stop on the trilobal tripot bushing (2).

16. Position the large boot retaining clamp around the inboard boot (4).
17. Engage the inboard boot (4).

Important: The halfshaft inboard boot (2) must not be dimpled, stretched out or out of shape in any way. If the halfshaft- inboard boot (2) is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing to equalize the pressure. Shape the halfshaft inboard boot (2) properly by hand. Remove the thin, flat, blunt tool.





18. Position joint assembly at the proper vehicle dimension.

Important: Align the following items while latching:
^ The halfshaft inboard boot (3)
^ The housing (1)
^ The large clamp (2)





19. Latch the boot retaining clamp (2) using J 35566.