Assembly
ASSEMBLY1. 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.
NOTICE: 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 C/V 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.
IMPORTANT: Joint must be assembled with convoluted retainer in position. Boot damage 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 (0.85inch).
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.
NOTICE: 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 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 (.102 inch).