For 1990-2009 cars

### Disassembly Procedure

#### Tools Required

• | J 8059 Snap Ring Pliers

• | J 38868 Stub Shaft Removal

• | J 6125 Impact Slide Hammer

Important: The transaxle stub shaft may disengage from the transaxle during halfshaft tripot removal. If this condition occurs, transaxle fluid may leak from the transaxle through the stub shaft location.

1. Perform the following steps if the transaxle stub shaft has disengaged into the female tripot housing on removal from transaxle.

Important: Never reuse the old snap ring.

2. Remove the snap ring from the stub shaft. Discard the snap ring.
3. Connect J 38868 to the snap ring groove on the stub shaft.

Connect J 6125 to the stub shaft removal tool.

4. Use the slide hammer to remove the shaft from the tripot housing.
5. Install new snap rings onto the stub shaft.
6. Remove the small boot retaining clamp from the halfshaft bar (1) with side cutters. Discard the boot retaining clamp.
7. Remove the larger boot retaining clamp from the tripot joint with side cutters. Dispose of the large boot retaining clamp.
8. Separate the boot from the trilobal tripot bushing at the large diameter.
9. Slide the boot away from the joint along the bar (1).
10. Remove the housing from the tripot joint spider and the bar (1).
11. Spread the spacer ring (2) using J 8059 .
12. Slide the spacer ring (3) and the spider assembly (2) back on the bar (4).
13. Remove the retaining ring (1) from the groove on the bar (4).
14. Slide the spider assembly (1) off of the bar (3).
15. Clean the following items with cleaning solvent:

• | The tripot balls

• | The needle rollers

• | The housing

16. Remove all traces of old grease and any contaminates.
17. Dry all the parts.
18. Remove the trilobal tripot bushing from the housing.
19. Remove the spacer ring (2) and the boot (3) from the bar (4).
20. Inspect the following parts for damage or wear:

• | The boot (3)

• | The spider assembly (1)

• | The housing

• | The trilobal tripot bushing

• | The tripot balls

• | The needle rollers

### Assembly Procedure

#### Tools Required

• | J 35910 Seal Clamp Tool

• | J 35566 Earless Seal Clamp Tool

• | J 8059 Snap Ring Pliers

1. Install the small boot retaining clamp (1) on the neck of the inboard boot. Do not crimp.
2. Slide the boot onto the halfshaft bar.
3. Position the neck of the boot in the boot groove on the 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.

4. Crimp the boot retaining clamp (1) using J 35910

Tighten
Crimp to 136 N·m (100 lb ft).

5. Check gap dimension, continue tightening until gap dimension is reached.
6. Install the spacer ring (2) on the halfshaft bar (1) and beyond the second groove.

Important: Ensure that the counterbored face of the spider assembly faces the end of the bar (1).

7. Slide the spider assembly toward the spacer ring as far as it will go on the bar.
8. Install the second retaining ring in the groove at the end of the bar (1) using J 8059 .
9. Slide the spider assembly (2) towards the end of the bar (4).
10. Reseat the first spacer ring (1) in the groove on the bar (4).
11. Place approximately half of the grease from the service kit in the boot. Use the remainder of the grease to repack the housing.
12. Install the trilobal tripot bushing to the housing. Ensure the trilobal tripot bushing is flush with the face of the housing.
13. Position the larger new clamp on the boot.
14. Slide the housing over the spider assembly on the bar.
15. Slide the large diameter of the 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 boot (2) must not be dimpled, stretched out or out of shape in any way. If the 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 boot properly by hand. Remove the thin, flat, blunt tool.

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

Important: Align the following items while latching:

• | The boot (3)

• | The housing (1)

• | The large clamp (2)

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