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PRE-RELEASE

Front Wheel Drive Shaft Outer Joint and Boot Replacement

Front Wheel Drive Shaft Outer Joint and Boot Replacement



Special Tools

• CH 48894 Drive Axle Boot Clamp Pliers

• DT 35910 Drive Axle Seal Clamp Pliers


For equivalent regional tools, refer to Special Tools .


Note

The outer Constant Velocity Joint is not serviced separately. If the CV joint is found to have excessive wear or damage, replace the wheel drive shaft as an assembly.


Removal Procedure


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

2. Clamp the drive axle shaft in a soft jawed vice.


3.
Warning

Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.


Using a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and the boot (3).


4. Use a pair of side cutters to remove and discard the boot clamp (4) from the boot (3) and the wheel drive shaft (5). Discard the boot clamp. Replace with NEW clamps.

5. Using a block of wood and a hammer, remove the CV joint (2) from the wheel drive shaft (1).


6. Remove the boot (1) from the wheel drive shaft (2).



Installation Procedure


1. Position the boot (1) on the wheel drive shaft (2).


2. Ensure that the boot (1) is properly seated in the groove (2) in the wheel drive shaft (3).


3. Place approximately half of the lubricant (2) inside the CV boot (1) and other half in the CV joint (3).


4. Using a block of wood and a hammer, install the CV joint on the wheel drive shaft (1).


5. Install the inboard boot clamp (4) on the boot (3) and the wheel drive shaft (5).


6. Install the outboard boot clamp (2) on the boot (3) and the CV joint housing (1).

7.
Note

Ensure that the boot clamp is properly positioned around the entire circumference of the boot.


Using the DT 35910 pliers (1), close the clamp (2) until the gap (3) measures 2.15 mm (0.85 in) .


8.
Note

Ensure that the boot clamp is properly positioned around the entire circumference of the boot.


Using the CH 48894 pliers (1), close the boot clamp (3).


9. Remove the wheel drive shaft from the bench vise.

10. Move the CV joint in a circular motion 4 to 5 times to distribute the lubricant.

11. Install the wheel drive shaft in the vehicle. Refer to Front Wheel Drive Shaft Replacement .


PRE-RELEASE