For 1990-2009 cars

## Wheel Drive Shaft Outer Joint and Boot Replacement Delphi

#### Tools Required

• | J 41398 CV Puller

• | J 2619-01 Slide Hammer

• | J 35910 Drive Axle Seal Clamp Pliers

• | J 8039-A Snap Ring Pliers

• | DT-47732 Drive Axle Swage Ring Clamp

### Disassembly Procedure

Important: Due to the helical splines on the shaft, disassembly and assembly of the joints will be difficult. Follow the instructions provided.

1. Remove the large seal retaining clamp from the CV joint with a hand grinder, taking care not to damage the housing. Discard the large seal retaining clamp.
2. Remove the small seal retaining clamp from the shaft with a hand grinder, taking care not to damage the housing. Discard the small seal retaining clamp.
3. Separate the CV joint seal from the CV joint race (2) at the large diameter.
4. Slide the seal away from the joint along the shaft.
5. Wipe the grease from the face of the CV joint inner race (1).
6. Before removing the CV joint assembly from the half shaft bar, perform the following procedure:

6.1. | Choose a reference mark (B) on the shaft.

6.2. | Measure the distance between the reference mark (B) and the face of the CV joint inner race (1). Make a note of this measurement (A).

6.3. | Mark as a reference the inboard side, toward the center of the half shaft bar, of the CV joint inner race (1).

6.4. | Inspect the CV joint inner race/shaft interface for the presence of a retaining ring. If present, remove the retaining ring using J 8039-A .

7. Clamp the shaft (2) into a vise.
8. Attach J 41398 to the threaded area of the outer race (2).
9. Attach J 2619-01 onto the outer end of J 41398 .
10. Use J 2619-01 to remove the CV joint from the shaft.
11. Remove J 2619-01 and J 41398 from the CV joint.

Important: Never reuse the retaining ring.

12. Remove the retaining ring from the shaft. Discard the retaining ring.
13. Remove the CV joint seal (1) from the shaft.
14. Place a brass drift against the CV joint cage (1).
15. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
16. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts.
17. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
18. Repeat this process to remove all 6 balls.
19. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows with the lands of the outer race (2).
20. Lift out the cage (4) and the inner race.
21. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
22. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
23. Dry all the parts.
24. Check the CV joint assembly for unusual wear, cracks, or other damage.
25. Replace any damaged parts.
26. Clean the shaft. Use a wire brush to remove any rust in the seal mounting area (grooves).

### Assembly Procedure

1. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race.
2. Hold the inner race 90 degrees to the centerline of the cage with the lands of the inner race (1) aligned with the windows of cage (2).
3. Insert the inner race into the cage.
4. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows (3) with the lands of the outer race (2).

Important: Ensure that the inner race is oriented the same as prior to disassembly. Use the reference mark placed earlier.

5. Install the cage and the inner race into outer race.
6. Place a brass drift against the CV joint cage (1).
7. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
8. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts.
9. Repeat this process to install all 6 balls.
10. Pack the CV joint with half of the grease supplied in the service kit.
11. Install the new swage ring (2) on the neck of the seal (3). Do not crimp.
12. Clean the shaft (1). Use a wire brush to remove any rust in the seal mounting area (grooves).
13. Slide the CV joint seal (3) onto the shaft (1). Expose the reference mark (4) by sliding the CV joint seal (3) up the shaft (1) toward the tripot end.
14. Position the large seal retaining clamp around the joint seal.
15. Place the new retaining ring onto the shaft.
16. While supporting the tripot assembly, place the wheel drive shaft assembly onto the arbor press with the CV assembly under the press head.
17. Lower the arbor press head onto the CV joint assembly until the press cannot move any further. This ensures that the retaining ring engages in the inner race. Do not exceed 1 779 N (4,000 lb) press load during assembly.
18. Remove the wheel drive shaft assembly from the arbor press.
19. Measure the distance between the reference mark on the shaft (B) and the face of the CV joint inner race (1).
20. Compare the mark with the measurement made before disassembly.
21. Repeat the previous 4 steps if the current measurement does not match the measurement made before disassembly.
22. Place the new swage ring (2) onto the small end of the joint boot (1). Slide the boot (1) and the swage ring (2) onto the half shaft bar.
23. Position the small end of the boot (1) into the boot groove (3) on the half shaft bar.
24. Mount DT-47732 in a vise and proceed as follows:

24.1. | Position the outboard end (1) of the wheel drive shaft assembly in tool .

24.2. | Align the top of boot neck on the bottom die using the indicator.

24.3. | Place the top half of the DT-47732 on the lower half of the DT-47732 .

24.4. | Before proceeding, ensure there are no pinch points on the boot. This could cause damage to the boot.

24.5. | Insert the bolts (2).

24.6. | Tighten the bolts by hand until snug.

Notice: Refer to Fastener Notice in the Preface section.

25. Align the following items:

• | The shaft out board boot (1)

• | The shaft boot grooves

• | The swage ring (2)

Tighten
Tighten each bolt of DT-47732 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.

• | Place the remaining grease from the service kit inside the seal.

26. Mount DT-47732 in a vise and proceed as follows:

Measure approximately 17.5 mm (11/16 in) up from the bottom edge of the CV outer joint assembly.

27. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of CV joint.

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

28. Locate the seal lip to the ridge of the CV outer joint assembly as measured in the previous step.
29. Crimp seal retaining clamp (1) with J 35910 , a breaker bar (3), and a torque wrench (2).

Tighten
Tighten seal retaining clamp to 176 N·m (130 lb ft).

30. Check the gap dimension. Continue tightening until the correct gap dimension is reached. Dimension a = 2.3 mm (0.091 in).

## Wheel Drive Shaft Outer Joint and Boot Replacement GKN

#### Tools Required

J 35910 Drive Axle Seal Clamp Pliers

### Disassembly Procedure

1. Clamp the drive axle shaft in a soft jawed vice.
2. Use a flat-bladed tool and disengage the retaining tabs of the large seal clamp.
3. Discard the clamp.
4. Remove the small seal clamp using side cutters and discard the clamp.
5. Separate the constant velocity (CV) joint boot from the CV joint race at the large diameter.
6. Slide the boot away from the joint along the wheel drive shaft bar.
7. Wipe the excess grease from the face of the CV inner race.
8. Place a block of wood against the CV joint outer race and carefully tap on the CV joint to remove it from the wheel drive shaft bar.
9. Remove the seal from the wheel drive shaft bar.
10. Remove the CV joint retaining ring from the wheel drive shaft bar.
11. Place a brass drift against the CV joint inner race (1).
12. Tap gently on the brass drift with a hammer in order to tilt the joint race.
13. Remove the first bearing roller (2) when the CV race tilts.
14. Repeating the steps above, tilt the CV joint inner race to remove every other bearing roller.
15. Repeat the process to remove all 6 of the bearing rollers.
16. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (2). At the same time, align the cage windows (3) with the lands of the outer race.
17. Lift out the cage (4) and the inner race.
18. Remove the inner race (1) from the cage (2) by rotating the inner race upward.
19. Clean the following items thoroughly with a suitable solvent. Remove all traces of grease and contaminants.

• | The inner and outer race assemblies.

• | The CV joint cage.

• | The bearing rollers.

20. Dry all the parts with compressed air.
21. Inspect the CV joint assembly for the following:

• | Unusual wear

• | Cracks

• | Damage

22. Replace any damaged parts.
23. Clean the wheel drive shaft bar. Use a wire brush to remove any rust in the seal mounting grooves.

### Installation Procedure

1. Install the new small seal clamp (2) on the neck of the outboard seal (1). Do not clamp.
2. Slide the outboard seal onto the wheel drive shaft bar and position the neck of the outboard seal in the seal groove on the bar. The largest groove below the sight groove on the wheel drive shaft bar is the seal groove seal (3).

Important: Ensure that the seal clamp is properly positioned around the entire circumference of the seal.

3. Crimp the seal clamp using the J 35910 .
4. Measure the clamp end gap dimension. The gap should not exceed 2.15 mm (0.85 in).

Specification
The gap should not exceed 2.15 mm (0.85 in).

5. Put a light coat of grease from the service kit on the bearing roller grooves of the inner race and outer race.
6. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race (1) aligned with the windows of the cage (2) and insert the inner race into the cage.
7. Hold the cage and inner race 90 degrees to the center line of the outer race (1) and align the cage windows (3) with the lands of the outer race.

Important: Be sure that the retaining ring side of the inner race faces the wheel drive shaft bar.

8. Place the cage and the inner race into the outer race.
9. Insert the first bearing roller, then tilt the cage to insert every other bearing roller.
10. Repeat this process until all 6 bearing rollers are in place.
11. Install the CV joint retaining ring to the wheel drive shaft bar.
12. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.
13. Place a block of wood against the CV joint spindle and tap on the block of wood until the CV joint inner race engages the retaining ring.
14. Slide the large diameter of the seal over the outside of the CV race and locate the lip of the seal in the housing groove.
15. Install the large seal retaining clamp over the seal and close using the J 35910
16. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.

Specification
Dimension equals 1.9 mm (5/64 in).

17. Remove the wheel drive shaft from the bench vise.
18. Distribute the grease within the outer CV joint by rotating the joint in a circular motion four to five times.