Rear Wheel Drive Shaft Inner Joint and Boot Replacement RWD

Tools Required

This procedure is to be performed only after the wheel drive shaft has been removed from the vehicle. Refer to Rear Wheel Drive Shaft Replacement .

1. Wrap a shop towel around the half shaft bar (3).
2. Place the wheel drive shaft (3) horizontally in a bench vise.
3. Using a side cutter or other suitable tool, remove the large seal retaining clamp (4) from the inner joint seal (1) and discard the retaining clamp.
4. Using a side cutter or other suitable tool, remove the small seal retaining clamp (2) from the inner joint seal and discard the clamp.



5. Slide the seal (4) along the half shaft bar away from the joint face (2).
6. Wipe the grease from the face of the joint inner race, cage, balls, etc.
7. Using J 8059 , spread the ears of the joints inner race retaining ring (3).



8. Hold the inner joint horizontally to the shaft.
9. Position a brass drift on the inner race.
10. Carefully strike the brass drift with a hammer to remove the inner joint assembly from the wheel drive shaft.
11. Remove and discard both wheel drive shaft retaining rings from the axle shaft.



12. Remove the seal (1) from the wheel drive shaft (3).
13. Remove the small seal retaining clamp (2) from the wheel drive shaft (3).
14. Remove the wheel drive shaft (3) from the vise.
15. Wrap a shop towel around the joint outer race splined shaft.
16. Place the outer race vertically in a bench vise.

Important: All traces of old grease and any contaminates must be removed.

17. Clean the following parts thoroughly with clean solvent:

•	The inner race

•	The outer race

•

The cage

•

The balls

•	The axle shaft exposed end

18. Thoroughly air dry all of the parts.
19. Inspect the following parts for damage and/or wear:

•	The inner race

•	The outer race

•

The cage

•

The balls

•	The axle shaft exposed end

1. Insert approximately 60 percent of the grease from the service kit into the inner joint.

1.1.	Spread 60 percent the grease onto the ball tracks, the balls, the cage, and the inner race.

1.2.	Spread the remainder of the grease into the bottom of the outer race.

2. Remove the inner joint from the bench vise.
3. Wrap a shop towel around the wheel drive shaft.
4. Place the wheel drive shaft horizontally in a bench vise.



5. Install a new small seal retaining clamp (2) onto the wheel drive shaft (3).
6. Slide the seal (1) onto the wheel drive shaft.



7. Place the new large retaining clamp over the large end of the seal (3).
8. Install the new wheel drive shaft large retaining ring onto drive shaft.
9. Seat the new wheel drive shaft large retaining ring into the large ring groove.
10. Install the new wheel drive shaft small retaining ring onto drive shaft.
11. Seat the new wheel drive shaft small retaining ring into the small ring groove.
12. Push the inner joint assembly (2) onto the wheel drive shaft until the small retaining ring (3) seats itself in the retaining groove on the wheel drive shaft.



13. Insert the remaining grease from the service kit into the seal.



14. Position the small seal retaining clamp (2) onto the neck of the seal (1).
15. Position the seal and small retaining clamp to the axle shaft (3) as shown.

Notice: Refer to Fastener Notice in the Preface section.





Important: The seal retaining clamp must not be over-tightened or under-tightened.

16. Using the J 42572  (1), crimp the small seal retaining clamp.

Tighten
Tighten the small seal clamp until the base of the omega ohms shape has a gap of 1 mm (0.039 in).

The clamping hold time must be no less than 2 seconds.





Important: The inner boot must not be dimpled, stretched, or out of shape in any way. If necessary, equalize the air pressure in the inner boot and shape properly by hand.

17. Position the large seal retaining clamp (1) onto the seal (2).
18. Position the seal and large retaining clamp to the joints can boot groove (3) as shown.



19. Measure the distance (1) between the seal edges.

Specification
88.6 mm (3.50 in)





Important: The seal must not be dimpled, stretched, or otherwise deformed.

20. Inspect the seal for proper shape.

If the seal is not shaped correctly, equalize the pressure in the seal by lifting the seal edge slightly and shape the seal properly by hand.

21. Inspect the seal for damage.

If the seal has been cut or punctured during assembly, you must discard and replace the seal.

Important: The seal retaining clamp must not be over-tightened or under-tightened.

22. Using the J 42572  (1), crimp the large seal retaining clamp.

Tighten
Tighten the large seal clamp until the base of the omega ohms shape has a gap of 1 mm (0.039 in).

23. Inspect the inner joint for smooth operation. This will also distribute the grease within the joint.

23.1.

Hold the wheel drive shaft vertically, with the inner joint at the bottom.

23.2.

Rotate the wheel drive shaft 4 or 5 times in a circular motion.

23.3.

Install the wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement .

Rear Wheel Drive Shaft Inner Joint and Boot Replacement AWD

Tools Required

J 42572 Drive Shaft Seal Clamp Pliers

This procedure is to be performed only after the wheel drive shaft has been removed from the vehicle. Refer to Rear Wheel Drive Shaft Replacement .

1. Wrap a shop towel around the axle shaft.
2. Place the wheel drive shaft horizontally in a bench vise.
3. Using a side cutter or other suitable tool, remove the large seal retaining clamp from the inner joint seal and discard the clamp.
4. Using a side cutter or other suitable tool, remove the small seal retaining clamp from the inner joint seal and discard the clamp.
5. Separate the seal from the inner joint outer race at the large diameter end.
6. Slide the seal away from the joint face.
7. Wipe the grease from the face of the joint inner race, cage, balls, etc.



8. Remove the inner joint from the axle shaft using the following steps:

8.1.	Hold the inner joint housing horizontally to the shaft.

8.2.	Position a brass drift on the inner race.

8.3.	Carefully strike the brass drift with a hammer to compress the axle shaft retaining clip.

8.4.	Continue to carefully strike the brass drift in order to remove the inner joint from the axle shaft.




9. Remove and discard the axle shaft retaining ring from the axle shaft.



10. Remove the seal from the axle shaft.
11. Remove the wheel drive shaft from the vise.
12. Wrap a shop towel around the joint outer race splined shaft.
13. Place the outer race vertically in a bench vise.

Important: All traces of old grease and any contaminates must be removed.

14. Clean the following parts thoroughly with clean solvent:

•	The inner race

•	The outer race

•

The cage

•

The balls

•	The axle shaft exposed end

15. Thoroughly air dry all of the parts.
16. Inspect the following parts for damage and/or wear:

•	The inner race

•	The outer race

•

The cage

•

The balls

•	The axle shaft exposed end

1. Insert approximately 60 percent of the grease from the service kit into the inner joint.

1.1.	Spread the grease onto the ball tracks, the balls, the cage, and the inner race.

1.2.	Spread the remainder of the grease into the bottom of the outer race.

2. Remove the inner joint from the bench vise.



3. Wrap a shop towel around the axle shaft.
4. Place the wheel drive shaft horizontally in a bench vise.
5. Install a new small seal retaining clamp onto the axle shaft.
6. Install the seal onto the axle shaft.



7. Install a new retaining ring to the axle shaft.



8. Position the inner joint horizontally.
9. Engage the inner race splines onto the axle shaft splines.
10. Compress the axle shaft ring spacer.

10.1.

Press the end of the retaining ring, using a flat-bladed tool, into the axle shaft groove while firmly pressing the inner joint onto the axle shaft.

10.2.

Continue to work around the retaining ring until it is compressed.





Important: The axle shaft and inner race must be fully seated to each other.

11. Install the inner joint to the axle shaft.

11.1.

Position a wood block over the end of the inner joint threaded shaft.

11.2.

Use a hammer to carefully drive the inner joint onto the shaft.

11.3.

Continue to drive the inner joint until the inner joint seats fully onto the axle shaft.




12. Position the small seal retaining clamp (2) into the boot (1).
13. Position the seal and small retaining clamp to the boot groove on the wheel axle shaft (3).

Notice: Refer to Fastener Notice in the Preface section.





Important: The seal retaining clamp must not be over-tightened or under-tightened.

14. Using the J 42572  (1), crimp the small seal retaining clamp.

Tighten
Tighten the small seal clamp until the base of the omega ohms shape has a gap of 1 mm (0.039 in).




15. Insert the remaining grease from the service kit into the seal.



16. Position the large seal retaining clamp (1) onto the seal (2).
17. Position the seal and large retaining clamp to the joint outer race (3) as shown.



18. Position the joint assembly to the proper vehicle dimension.
19. Measure the distance (1) between the seal edges.

Specification
86.85 mm (3.42 in)





Important: The seal must not be dimpled, stretched, or otherwise deformed.

20. Inspect the seal for proper shape.

If the seal is not shaped correctly, equalize the pressure in the seal by lifting the seal edge slightly and shape the seal properly by hand.

21. Inspect the seal for damage.

If the seal has been cut or punctured during assembly, you must discard and replace the seal.

Important: The seal retaining clamp must not be over-tightened or under-tightened.

22. Using the J 42572 , crimp the large seal retaining clamp.

Tighten
Tighten the large seal clamp until the base of the omega ohms shape has a gap of 1 mm (0.039 in).

23. Inspect the inner joint for smooth operation. This will also distribute the grease within the joint.

23.1.

Hold the wheel drive shaft vertically, with the inner joint at the bottom.

23.2.

Rotate the wheel drive shaft 4 or 5 times in a circular motion.

23.3.

Install the wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement .