For 1990-2009 cars

## Wheel Drive Shaft Inner Joint and Boot Replacement Round Retaining Ring

### Disassembly Procedure

#### Tools Required

J 8059 Snap Ring Pliers

Important: Do not cut through the halfshaft inboard boot and damage sealing surface of the outer housing and the trilobal tripot bushing.

1. Disconnect the small boot retaining clamp from the halfshaft bar using a side cutter. Discard the small boot retaining clamp.
2. Remove the larger boot retaining clamp from the tripot joint with side cutter and dispose.
3. Separate the halfshaft inboard boot from the trilobal tripot bushing at the large diameter.
4. Slide the boot away from the joint along the halfshaft bar (4).
5. Remove the housing from the tripot joint spider and the halfshaft bar (4).
6. Spread the spacer ring (3) with J 8059 .
7. Slide the spacer ring (3) and tripot joint spider (2) back on halfshaft bar (4).
8. Using J 8059 , remove the spacer ring (1) from the groove and the halfshaft bar (4).
9. Slide the tripot joint spider (1) assembly off the halfshaft bar (3).
10. Clean the following items with cleaning solvent:

• | The tripot balls

• | The needle rollers

• | The housing

11. Remove all traces of old grease and any contaminates.
12. Dry all of the parts.
13. Remove the trilobal tripot bushing from the housing.
14. Remove the spacer ring (2) and the boot (3) from the halfshaft bar (4).
15. Inspect the following parts for damage or wear:

• | The halfshaft inboard boot (3)

• | The tripot joint spider assembly (1)

• | The housing

• | The trilobal tripot bushing

• | The tripot balls

• | The needle rollers

### Assembly Procedure

#### Tools Required

• | J 35910 Eared Clamp Tool

• | J 35566 Earless Seal Clamp Tool

• | J 8059 Snap Ring Pliers

1. Install the small boot retaining clamp on the neck of the halfshaft inboard boot. Do not crimp.
2. Slide the inboard boot onto the halfshaft bar.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Position the neck of the inboard boot in the boot groove on the halfshaft bar.

Tighten
Crimp the boot retaining clamp (1) using J 35910 to 136 N·m (100 lb ft).

4. Install the spacer ring (3) on the halfshaft bar (4) into the second groove.
5. Slide the tripot joint spider assembly (2) toward the spacer ring (3) as far as it will go on the halfshaft bar (4).
6. Install the spacer ring (2) in the groove of the halfshaft bar (1) using J 8059 .
7. Place approximately half of the grease from the service kit in the inboard boot. Use the remainder of the grease to repack the housing.
8. Install the trilobal tripot bushing to the housing. Ensure the trilobal tripot bushing is flush with the face of the housing.
9. Position the larger new clamp on the inboard boot.
10. Slide the housing over the tripot joint spider assembly on the halfshaft bar.
11. Slide the large diameter of the inboard boot (2), with the larger clamp in place (3), over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.

Important: The halfshaft inboard boot (2) must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard boot (2) is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing to equalize the pressure. Shape the halfshaft inboard boot properly by hand. Remove the tool.

12. Position the joint assembly at the proper vehicle dimension.

Important: Align the following items while latching:

• | The halfshaft inboard boot (3)

• | The housing (1)

• | The large clamp (2)

13. Latch the boot retaining clamp (2) with J 35566 .