Drive Axle Assembly

1. Install tri-pot joint and boot.
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 boot mounting area (grooves), wire brush this area.
c. Install small boot retaining clamp on neck of boot. Do not crimp.
d. Slide boot onto shaft and locate neck of boot in proper position in boot groove on axle shaft.
e. Crimp boot retaining clamp with Axle Clamp Installer 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 end 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 (1) 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 Check Valve (C/V) Joint Snap Ring Pliers 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 boot and use the remainder to repack tri-pot housing.
l. Install convolute retainer (supplied with service kit) over boot.

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

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





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

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.





q. Place large boot retaining clamp around boot and close with Axle Boot Clamp Installer 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 inch) 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.





c. Place drive shaft in a vice with brass jaws and start damper onto the drive shaft by hand.

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

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 Axle Boot Clamp Installer SA9164C.

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

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





d. Measure clamp end gap dimension and repeat step C if necessary.
e. Place approximately half of grease (provided in kit) inside boot and repack CV with remaining grease.





f. Position large boot retaining clamp around boot.

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 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 outer race to equalize pressure. Shape boot properly by hand and remove tool.

i. Crimp retaining clamp with Axle Clamp Installer SA9203C (or equivalent).

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

j. Measure clamp end gap dimension and repeat step if necessary. Dimension should not exceed 2.6 mm (0.102 inch).





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