Special Tools

1. Remove the wheel drive shaft from the vehicle. Refer to Wheel Drive Shaft Replacement.



2. Wrap a shop towel around the axle shaft.
3. Place the wheel drive shaft horizontally in a bench vise.
4. Using the J 46588 tool , remove and discard outboard boot clamp.
5. Using a side cuter, remove and discard the inboard boot clamp.
6. Remove the outboard boot from the CV joint housing.
7. Reposition the wheel drive shaft vertically in the bench vise so the inboard joint is up.
8. Slide the joint outer race down toward the vise.
9. Using a small flat bladed screwdriver, remove the retaining ring from the outer race.
10. Position the retaining ring along the axle shaft away from the outer race.




Note: Use the seal to catch any balls which may fall out of the cage and inner race when the outer race is removed.

11. Remove the outer race from the axle shaft.



12. Remove any remaining balls from the cage and inner race and those that fell into the boot.



13. Position the wheel drive shaft horizontally in the bench vise.
14. Remove the outer race retaining ring from the axle shaft.
15. Remove the snap ring from the axle shaft.



16. Align the cage lands with the inner race ball tracks.
17. Reposition the cage along the axle shaft away from the inner race.
18. Wipe the lubricant from the inner race.
19. Using a three jaw puller, remove the inner race from the wheel drive shaft.



20. Remove the cage from the wheel drive shaft.



21. Remove the boot from the wheel drive shaft.
22. Remove the wheel drive shaft from the bench vise.

Note: All traces of the old lubricant and any contaminates must be removed.

23. Clean the following thoroughly with clean solvent:

•	The inner race

•	The outer race

•

The cage

•

The balls

•	The wheel drive shaft exposed end.

24. Thoroughly air dry all the parts.

Caution: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

1. Wrap a shop towel around the wheel drive shaft.
2. Place the wheel drive shaft horizontally in a bench vise.
3. Install the new inner boot clamp onto the wheel drive shaft.
4. Install the boot onto the wheel drive shaft.



5. Install the cage onto the wheel drive shaft so the smaller diameter end faces the vise.




Note: The inner race spline relief must face away from the end of the axle shaft. Also, ensure to install the inner race spline relief side onto the axle shaft first.

6. Install the inner race splines onto the axle shaft splines.

Note: Ensure that the inner race is fully seated on the wheel drive shaft and the groove for the retaining ring is exposed.

7. Using a hammer and a block of wood, drive the inner race onto the axle shaft.



8. Install the snap ring to the axle shaft.
9. Position the cage so the cage lands align with the inner race ball tracks.
10. Install the cage onto the inner race.
11. Position the cage windows to align with the inner race ball tracks.



12. Insert approximately 60 percent of the lubricant from the service kit into the outer race.



13. Position the wheel drive shaft vertically in the bench vise so the inner joint end is up.
14. Apply a small amount of the lubricant from the service kit to the cage windows and inner race ball tracks.
15. Insert the remaining lubricant from the service kit into the boot.




Note: Position the retaining ring below the cage (toward the vise).

16. Install the outer race retaining ring onto the wheel drive shaft.

Note: Use the boot to keep the balls in position if necessary.

17. Install the balls through the cage windows to the inner race ball tracks.



18. Install the outer race onto the wheel drive shaft.

18.1.

Be careful not to allow the grease in the outer race to leak out.

18.2.

Align the outer race ball tracks to the balls.

18.3.

Slide the outer race down over the balls.

19. Position the wheel drive shaft horizontally in the bench vise.
20. Engage the outer race retaining ring.

20.1.

Slide the outer race toward the vise.

20.2.

Insert the outer race retaining ring into the groove along the outer edge of the outer race.

20.3.

Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track).

21. Position the large diameter end of the boot onto the outer race.



22. Position the small boot clamp (3) onto the neck of the boot (4).
23. Position the boot and the clamp to the axle shaft (2).
24. Measure the distance (1)  2.5 mm (0.10 in) between the edge of the boot and the edge of the last axle shaft groove closing edge adjust fit accordingly.




Note: The boot clamp must not be over-tightened or under-tightened.

25. Using the J 42572 pliers  (1), close the boot clamp until gap (a) measures 2 and 3 mm (0.079 and 0.118 in), with a difference in the gap width from side to side no greater than 0.4 mm (0.016 in)..



26. Measure the distance (1)  224-228 mm (8.82-8.98 in) between the end of the boot and the end of the joint outer race and adjust the plunging motion of the joint accordingly.



27. Position the large boot retaining clamp (2) onto the boot (3).
28. Position the boot and large retaining clamp to the joint outer race (4) as shown.
29. Measure the distance (1)  0.8 mm (0.03 in) between the edge of the boot and the edge of the joint outer race last groove closing edge and adjust the fit accordingly.

Note: The boot must not be dimpled, stretched or out of shape in any way. If the seal is NOT shaped correctly, equalize the pressure in the boot and shape the boot properly by hand.

30. Inspect the boot for proper shape.

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

31. Inspect the boot for damage.



32. Align the following items while latching:

•	The wheel drive shaft inboard seal (2)

•	The tripot housing

•	The large boot retaining clamp (3)

Note: Ensure that the latching tangs are fully engaged in the large boot clamp band.

33. Using the J 46588 tool  (1), latch the boot clamp.
34. Remove the wheel drive shaft from the bench vise.
35. Distribute the lubricant within the inner CV joint by moving the joint back and forth four or five times..
36. Inspect the inner CV joint and wheel drive shaft for smooth operation.

36.1.

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

36.2.

Rotate the wheel drive shaft four or five times in a circular motion.

37. To install the wheel drive shaft into the vehicle, refer to Wheel Drive Shaft Replacement.