For 1990-2009 cars

## Wheel Drive Shaft Outer Joint and Boot Replacement GKN

#### Special Tools

J 35910 Drive Axle Seal Clamp Pliers

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

### Disassemble Procedure

1. Remove the wheel drive shaft from the vehicle. Refer to Wheel Drive Shaft Replacement.
2. Clamp the drive axle shaft in a soft jawed vice.

Caution: 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.

3. Use a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and the boot (3).
4. Using a pair of side cutters, remove and discard the boot clamp (4) from the boot (3) and the wheel drive shaft (5). 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).
7. Inspect the outer CV joint for damage and wear. Refer to Wheel Drive Shaft Outer Joint Inspection.

### Assemble 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 the lubricant (2) inside the CV joint boot (1) and the 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 boot clamp (4) on the boot (3) and the wheel drive shaft (5).
6. Install the boot clamp (2) on the boot (3) and the CV joint housing (1).

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

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

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

8. Using the J 35910 pliers (1), close the boot clamp (3) until the gap measures 1.9 mm (0.070 in)..
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 Wheel Drive Shaft Replacement.

## Wheel Drive Shaft Outer Joint and Boot Replacement Delphi

#### Special Tools

• | DT 47732 Drive Axle Swage Ring Clamp

• | J 2619-01 Slide Hammer

• | J 8039-A Snap Ring Pliers

• | J 35910 Drive Axle Clamp Pliers

• | J 41398 Constant Velocity Joint Puller

Note: The Constant Velocity Joint and it's internal parts are not serviced separately. If the CV jointer it's related parts are found to be damaged or have excessive wear, replace the wheel drive shaft as an assembly.

### Disassemble Procedure

1. Remove the wheel drive shaft from the vehicle. Refer to Wheel Drive Shaft Replacement.
2. Install the wheel drive shaft (2) into a vise.

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

Caution: 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.

3. Using a hand grinder, remove and discard the inner (4) and outer (2) boot clamps.
4. Separate the CV joint boot from the CV joint race (2) at the large diameter.
5. Slide the boot away from the joint along the wheel drive shaft.
6. Remove the lubricant from the face of the CV joint inner race (1).
7. Perform the following procedures before removing the CV joint assembly from the wheel drive shaft:

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

7.2. | 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).

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

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

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.
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).

### Assemble 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).

Note: 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.

Caution: Refer to Fastener Caution 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).