Wheel Drive Shaft Overhaul

Tools Required
• SA9198C C/V Joint Snap Ring Pliers
• J 22610 Clamp Pliers
• SA9161C Axle Boot Clamp Installer
• SA9203C Axle Clamp Installer

Disassembly Procedure

Important

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

1. Clamp the drive 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 the outer CV joint and the joint boot.
1. Use a hammer and chisel or a flat-blade screw driver to disengage the outer band from the inner band at the retainer peg on both large and small boot clamps and discard the clamps.
2. Separate the joint boot from the CV joint race at the large diameter and slide the boot away from the joint along the axle shaft.
3. Wipe excess grease from the face of the CV inner race.




4. Spread the ends on the race retaining ring with the SA9198C or equivalent, and remove the CV joint assembly from the axle shaft.
5. Remove the boot from the axle shaft.




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




5. Disassemble the CV joint.
1. Using a brass drift, gently tap on cage (1) until it is tilted enough to remove the first ball.
2. Remove the remaining balls in a similar manner.
3. With all balls removed, pivot the cage and inner race (2) at 90 degrees to the center line of the outer race (3) with the cage windows aligned with the lands of the outer race, lift out the cage and the inner race.
4. Rotate the inner race up and out of the cage.
5. Thoroughly degrease all CV joint parts and allow them to dry prior to assembly.
6. Assemble the CV joint.
1. Inspect the parts for unusual wear, cracks and other damage. Replace the joint assembly if needed.
2. Put a light coat of recommended grease on the inner and outer race grooves.
3. Insert and rotate the inner race into the cage.
4. Install the cage and the inner race into the outer race with the windows of the cage aligned with the lines of the outer race.
5. Install the balls using a brass drift to gently rotate and position the cage and the inner race.
6. If removed, install the race retaining ring into the inner race.
7. Pack the assembled joint with grease provided in the service kit. The amount of grease supplied with service kits has been pre-measured for each application.




7. Remove the tri-pot joint and the joint boot.
1. Cut the eared boot retaining clamp on the tri-pot boot with side cutters and discard.
2. Remove the earless clamp, using a small-blade screwdriver and discard.




3. Separate the boot from the tri-pot housing at the large diameter and slide the boot away from the joint along the axle shaft.
4. Wipe excess grease from the face of the tri-pot spider and the inside of the tri-pot housing.
5. Remove the tri-pot housing from the spider and shaft.




6. Spread the spacer ring (1) with the SA9198C or equivalent , and slide the spacer ring and tri-pot spider back on the axle as shown.

Notice

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

7. Remove the spider retaining ring (2) from the groove on the axle shaft and slide the spider assembly off of the shaft.
8. Remove the boot from the axle shaft.
9. Thoroughly degrease the housing and allow the housing to dry prior to assembly.

Assembly Procedure

1. Install the tri-pot joint and boot.
1. Inspect the tri-pot joint components for unusual wear, cracks, and other damage. Replace damaged components as needed.
2. Clean the shaft. If rust is present in the boot mounting area, grooves, wire brush this area.
3. Install the small boot retaining clamp on the neck of the boot. Do not crimp.
4. Slide the boot onto the shaft and locate the neck of the boot in the proper position in the boot groove on the axle shaft.
5. Crimp the boot retaining clamp with the SA9203C or equivalent as shown.





Important

Check the clamp location during the crimp operation to ensure it is positioned correctly around the entire circumference.

6. Measure the clamp end gap, and repeat the step if necessary.
7. Install the spacer ring on the axle shaft and beyond the second groove as shown.
8. Slide the tri-pot spider assembly past the spider (1) retaining ring groove.

Important

Ensure that the retaining ring side of the inner race faces the axle shaft prior to installation.

9. Install the spider retaining ring in the groove of the axle shaft with the SA9198C or equivalent.




10. Slide the tri-pot spider towards the end of the shaft and reseat the spacer ring in the groove on the axle.
11. Place approximately half of the grease, provided in kit, inside the boot and use the remainder to repack the tri-pot housing.
12. Install the convolute retainer, supplied with service kit, over boot.

Important

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

13. Position the boot retaining clamp around the large diameter of the boot.
14. Slide the tri-pot housing over the tri-pot spider assembly on the shaft.
15. Slide the large diameter of the boot over the outside of the tri-pot housing and locate the lip of the boot in the 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.

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




17. Place the large boot retaining clamp around the boot and close with the SA9161C or equivalent.




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

Important

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

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





Important

Lubricate the shaft with a liquid detergent, example, liquid dish washing detergent, to aid in damper installation.

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

Important

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

5. Remove the masking tape.
6. Secure the damper in place by crimping the retaining clamp with the J 22610 .




3. Install the outer CV joint and boot.
1. Install the small retaining clamp on the neck of the new boot. Do not crimp.
2. Slide the boot onto the axle shaft and locate the neck of the boot in the proper position in the boot groove on the axle shaft.
3. Crimp the boot retaining clamp with the SA9203C or equivalent.

Important

Inspect the clamp location during the crimp operation to ensure it is positioned correctly around the entire circumference.

4. Measure the clamp end gap dimension and repeat step C if necessary.
5. Place approximately half of the grease, provided in the kit, inside the boot and repack the CV with the remaining grease.




6. Position the large boot retaining clamp around the boot.

Important

Ensure that the retaining ring side of the inner race faces the axle shaft prior to installation.

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




8. Slide the large diameter of the boot over the outside of the CV joint race and locate the lip of the boot in the 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.

9. Crimp the retaining clamp with the SA9203C or equivalent.

Important

Inspect the clamp location during the crimp operation to ensure it is positioned correctly around the entire circumference.

10. Measure the clamp end gap dimension and repeat the step if necessary. The dimension should not exceed 2.6 mm (0.102 in)
11. If removed, position deflector ring at CV joint outer race.
12. Using Axle Deflector Ring Installer SA9160C (or equivalent) and M20 x 1.5 nut, tighten nut until deflector bottoms against shoulder of CV outer race.