Drive Axle Disassembly

NOTICE: Use soft metal or wood in between vice jaws to protect the shaft.





1. Clamp the axle shaft in a vice.





2. If drive axle has a damaged deflector ring, remove the ring from the CV outer race with a brass drift and hammer, as shown, and discard. (Non ABS shown.)





3. Remove outer CV joint and joint seal.
a. Use a hammer and chisel or a flat bladed screw driver to disengage outer band from inner band at retainer peg on both large and small seal clamps and discard clamps.
b. Separate joint seal from CV joint race at large diameter and slide seal away from joint along axle shaft.
c. Wipe excess grease from face of CV inner race.
d. Spread ears on race retaining ring with SA9198C (or equivalent), and remove CV joint assembly from axle shaft.





e. Remove seal from axle shaft.





4. If drive axle is equipped with a dynamic damper, and damper or axle shaft is being replaced, remove damper using an arbor press.





5. Disassemble CV joint.
a. Using a brass drift, gently tap on cage until tilted enough to remove first ball.
b. Remove remaining balls in similar manner.
c. With all balls removed, pivot cage and inner race at 90 degrees to center line of outer race with cage windows aligned with lands of outer race, lift out cage and inner race.
d. Rotate inner race up and out of cage.
e. Thoroughly degrease all CV joint parts and allow to dry prior to assembly.
6. Assemble CV joint.
a. Inspect parts for unusual wear, cracks and other damage. Replace joint assembly if needed.
b. Put a light coat of recommended grease on inner and outer race grooves.
c. Insert and rotate inner race into cage.
d. Install cage and inner race into outer race with windows of cage aligned with lines of outer race.
e. Install balls using a brass drift to gently rotate and position cage and inner race.
f. If removed, install race retaining ring into inner race.
g. Pack assembled joint with grease provided with service kit. (The amount of grease supplied with service kits has been pre-measured for each application.)





7. Remove tri-pot joint and joint seal.
a. Cut eared seal retaining clamp on tri-pot seal with side cutter and discard.
b. Remove earless clamp, using a small-bladed screwdriver and discard.





c. Separate seal from tri-pot housing at large diameter and slide seal away from joint along axle shaft.
d. Wipe excess grease from face of tri-pot spider and inside of tri-pot housing.
e. Remove tri-pot housing from the spider and shaft.





f. Spread spacer ring with SA9198C (or equivalent) and slide spacer ring and tri-pot spider back on axle as shown.

NOTICE: Handle the tri-pot spider assembly with care. Tri-pot balls and needle rollers may separate from spider trunnions.

g. Remove spider retaining ring from groove on axle shaft and slide spider assembly off of shaft.
h. Remove seal from axle shaft.
i. Thoroughly degrease the housing and allow to dry prior to assembly.