Drive Axle Assembly

1. Install tri-pot joint and seal.
a. Inspect tri-pot joint components for unusual wear, cracks, and other damage, and replace any needed components.
b. Clean the shaft. If rust is present in the seal mounting area (grooves), wire brush this area.
c. Install small seal retaining clamp on neck of seal. Do not crimp.
d. Slide seal onto shaft and locate neck of seal in proper position in seal groove on axle shaft.
e. Crimp seal retaining clamp with SA9203C (or equivalent) as shown.

IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.

f. Measure clamp ear gap, and repeat step e if necessary.
g. Install spacer ring on axle shaft and beyond second groove as shown.
h. Slide tri-pot spider assembly past spider retaining ring groove.

NOTICE: Be sure that counterbored surface of tri-pot spider faces end of shaft after installation.





i. Install spider retaining ring in groove of axle shaft with SA9198C (or equivalent).





j. Slide tri-pot spider towards end of shaft and reseat spacer ring in groove on axle.
k. Place approximately half of the grease (provided in kit) inside seal and use the remainder to repack tri-pot housing.
l. Install convolute retainer (supplied with service kit) over seal.

IMPORTANT: Joint must be assembled with convolute retainer in position. Seal damage will result if joint is not assembled to correct dimension.

m. Position seal retaining clamp around large diameter of seal.
n. Slide tri-pot housing over tri-pot spider assembly on shaft.
o. Slide large diameter of seal over outside of tri-pot housing and locate lip of seal in housing groove.





NOTICE: Seal must not be dimpled, stretched, or out of shape in any way. If seal is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between large seal opening and housing to equalize pressure. Shape seal properly by hand and remove tool.

p. Position tri-pot assembly at proper vehicle dimension as shown.





q. Place large seal retaining clamp around seal and close with SA9161C (or equivalent).





2. If dynamic damper is being replaced or installed:
a. Thoroughly clean and degrease the drive shaft.

IMPORTANT: Drive shaft must be clean and free of grease to ensure the damper is secure to the drive shaft after installation.

b. Measure 202 mm (7.95 in.) from the outboard end of the drive shaft for location of where damper will be installed. Mark this location with a piece of masking tape.





IMPORTANT: Lubricate shaft with a liquid detergent (example, liquid dishwashing detergent) to aid in damper installation.

c. Place drive shaft in a vice with brass jaws and start damper onto the drive shaft by hand.
d. Work damper onto drive shaft by twisting it back and forth. Align inboard edge of damper with installed masking tape.

IMPORTANT: If more than moderate pressure is required to move the damper, not enough liquid detergent has been applied.

e. Remove masking tape.
f. Secure damper in place by crimping retaining clamp with SA9164C.





3. Install outer CV joint and seal.
a. Install small retaining clamp on neck of new seal. Do not crimp.
b. Slide seal onto axle shaft and locate neck of seal in proper position in seal groove on axle shaft.
c. Crimp seal retaining clamp with SA9203A (or equivalent).

IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.

d. Measure clamp ear gap dimension and repeat step C if necessary.
e. Place approximately half of grease (provided in kit) inside seal and repack CV with remaining grease.
f. Position large seal retaining clamp around seal.

NOTICE: Be sure that retaining ring side of inner race faces axle shaft prior to installation.





g. Push CV joint onto axle shaft until retaining ring is seated in groove on axle shaft.





h. Slide large diameter of seal over outside of CV joint race and locate lip of seal in housing groove.

NOTICE: Seal must not be dimpled, stretched or out of shape in any way. If seal is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between large seal opening and outer race to equalize pressure. Shape seal properly by hand and remove tool.

i. Crimp retaining clamp with SA9203C (or equivalent).

IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.

j. Measure clamp ear gap dimension and repeat step if necessary.





k. If removed, position deflecting ring at CV joint outer race.
l. Using SA9160C (or equivalent) and a M20 x 1.5 nut, tighten nut until deflector bottoms against shoulder of CV outer race.