Tri-Pot Joint
TRI-POT JOINT^ TOOLS REQUIRED
- SA9161C Axle Boot Clamp Installer
- SA9198C CV Joint Snap Ring Pliers
- SA9203C Axle Boot Clamp Installer
DISASSEMBLY
Notice: Use soft metal or wood in between vice jaws to protect the shaft.
1. Clamp the drive axle shaft in a vice.
2. Remove outer CV joint and joint boot.
2.1 Use a hammer and chisel or a flat blade screwdriver to disengage outer band from inner band at retainer peg on both large and small boot clamps and discard clamps.
2.2 Separate joint boot from CV joint race at large diameter and slide boot away from joint along axle shaft.
2.3 Wipe excess grease from face of CV inner race.
2.4 Using a rubber mallet, or block of wood and hammer, carefully tap on CV joint to remove from axle.
2.5 Remove boot from axle shaft.
3. Disassemble CV joint.
3.1 Using a brass drift, gently tap on cage until tilted enough to remove first ball.
3.2 Remove remaining balls in similar manner.
3.3 With all balls removed, pivot cage and inner race at 90° to center line of outer race with cage windows aligned with lands of outer race, lift out cage and inner race.
3.4 Rotate inner race up and out of cage.
3.5 Thoroughly degrease all CV joint parts and allow to dry prior to assembly.
4. Assemble CV joint.
4.1 Inspect parts for unusual wear, cracks and other damage. Replace joint assembly if needed.
4.2 Put a light coat of recommended grease on inner and outer race grooves.
4.3 Insert and rotate inner race into cage.
4.4 Install cage and inner race into outer race with windows of cage aligned with lines of outer race.
4.5 Install balls using a brass drift to gently rotate and position cage and inner race.
4.6 Pack assembled joint with grease provided in service kit. (The amount of grease supplied with service kits has been pre-measured for each application.)
5. Remove tri-pot joint and joint boot.
5.1 Cut eared boot retaining clamp on tri-pot boot with side cutters and discard.
5.2 Remove earless clamp, using a small-blade screwdriver and discard.
5.3 Separate boot from tri-pot housing at large diameter and slide boot away from joint along axle shaft.
5.4 Wipe excess grease from face of tri-pot spider and inside of tri-pot housing.
5.5 Remove tri-pot housing from the spider and shaft.
IMPORTANT: Handle the tri-pot spider assembly with care. Tri-pot balls and needle rollers may separate from spider trunnions.
5.6 Remove spider retaining ring from groove on axle shaft and slide spider assembly off of shaft.
5.7 Remove boot from axle shaft.
5.8 Thoroughly degrease the housing and allow to dry prior to assembly.
ASSEMBLY
1. Install tri-pot joint and boot.
1.1 Inspect tri-pot joint components for unusual wear, cracks, and other damage, and replace any needed components.
1.2 Clean the shaft. If rust is present in the boot mounting area (grooves), wire brush this area.
1.3 Install small boot retaining clamp on neck of boot. Do not crimp.
1.4 Slide boot onto shaft and locate neck of boot in proper position in boot groove on axle shaft.
1.5 Crimp boot retaining clamp with Axle Boot Clamp Installer SA9203C (or equivalent) as shown.
IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.
1.6 Measure clamp end gap, and repeat step 1.5 if necessary. Dimension should not exceed 2.15 mm (0.85 inch).
1.7 Slide tri-pot spider assembly past spider retaining ring groove until seated against shoulder.
IMPORTANT: Be sure that counterbored surface of tri-pot spider faces end of shaft after installation.
1.8 Install spider retaining ring in groove of axle shaft with CV Joint Snap Ring Pliers SA9198C (or equivalent).
1.9 Place approximately half of the grease (provided in kit) inside boot and use the remainder to repack tri-pot housing.
1.10 Install convoluted retainer (supplied with service kit,) over boot.
NOTICE: Joint must be assembled with convoluted retainer in position. Boot drainage will result if joint is not assembled correctly.
1.11 Position boot retaining clamp around large diameter of boot.
1.12 Slide tri-pot housing over tri-pot spider assembly on shaft.
1.13 Slide large diameter of boot over outside of tri-pot housing and locate lip of boot in housing groove.
NOTICE: Boot must not be dimpled, stretched, or out of shape in any way. If boot is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between large boot opening and housing to equalize pressure. Shape boot properly by hand and remove tool.
1.14 Place large boot retaining clamp around boot and close with Axle Boot Clamp Installer SA9161C (or equivalent).
2. Install outer CV joint and boot.
2.1 Install small retaining clamp on neck of new boot. Do not crimp.
2.2 Slide boot onto axle shaft and locate neck of boot in proper position in boot groove on axle shaft.
2.3 Crimp boot retaining clamp with Axle Boot Clamp Installer SA9203C (or equivalent).
IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.
2.4 Measure clamp end gap dimension and repeat step 2.3 if necessary. Dimension should not exceed 2.15 mm (0.85 inch).
2.5 Place approximately half of grease (provided in kit) inside boot and repack CV with remaining grease.
2.6 Position large boot retaining clamp around boot.
IMPORTANT: Be sure that retaining ring side of inner race faces axle shaft prior to installation.
2.7 Push CV joint onto axle shaft until retaining ring is seated in groove on axle shaft.
2.8 Slide large diameter of boot over outside of CV joint race and locate lip of boot in housing groove.
NOTICE: Boot must not be dimpled, stretched, or out of shape in any way. If boot is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between large boot opening and housing to equalize pressure. Shape boot properly by hand and remove tool.
2.9 Crimp retaining clamp with Axle Boot Clamp Installer SA9161C (or equivalent).
IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.
2.10 Measure clamp end gap dimension and repeat Substep 2.9 if necessary. Dimension should not exceed 2.6 mm (0.102 inch).