For 1990-2009 cars

#### Tools Required

• | SA9161C Drive Axle Boot Clamp Pliers

• | SA9203C Axle Boot Clamp Installer

### Disassembly Procedure

Notice: Use soft metal or wood in between vice jaws to protect the shaft.

1. Remove the wheel drive shaft from the vehicle. Refer to Wheel Drive Shaft Replacement .
2. Clamp the drive axle a shaft in a vice.
3. Use a hammer and chisel to disengage the outer band from the inner band at the retainer peg on large and small boot clamps. Discard the clamps.
4. Separate the joint boot from the CV joint race at the large diameter.
5. Slide the boot away from the joint along the axle shaft.
6. Wipe the excess grease from the face of the CV inner race.
7. Using a rubber mallet, or a hammer and a block of wood, carefully tap on the CV joint to remove it from the axle.
8. Remove the boot from the axle shaft.
9. Place a brass drift against the CV joint cage (1).
10. Tap gently on the brass drift with a hammer in order to tilt the joint cage (1).
11. Remove the first chrome alloy ball (2) when the CV cage tilts.
12. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
13. Repeat the process in steps 8 through 11 to remove all 6 of the chrome alloy balls.
14. 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.
15. Lift out the cage (4) and the inner race.
16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
17. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminants.

• | The inner and outer race assemblies

• | The CV joint cage

• | The chrome alloy balls

18. Dry all the parts.
19. Check the CV joint assembly for the following items:

• | Unusual wear

• | Cracks

• | Damage

20. Replace any damaged parts.
21. Clean the half shaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).

### Installation Procedure

1. Install the new swage ring (2) on the neck of the outboard seal (1). Do not swage.
2. Slide the outboard boot seal (1) onto the half shaft bar and position the neck of the outboard seal (1) in the seal groove on the half shaft bar. The largest groove below the sight groove on the half shaft bar is the seal groove seal (3).

Important: Check clamp location during crimp operation to make sure that it is properly positioned around the entire circumference.

3. Swage the swage ring with SA9161C Axle Boot Clamp Installer, (or equivalent).
4. Measure the swage end gap dimension and repeat step (3) if necessary. The gap should not exceed 2.15 mm (0.85 in).
5. Put a light coat of grease from the service kit on the ball groves in 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 half shaft bar.

8. Place the cage and the inner race into the outer race.
9. Insert the first chrome ball, then tilt the cage in the opposite direction to insert the opposing ball.
10. Repeat this process until all 6 balls are in place.
11. Place approximately half the grease from the service kit inside the outboard boot seal and pack the CV joint with the remaining grease.
12. Push the CV joint onto the half shaft bar until the retaining ring is seated in the groove on the half shaft bar.
13. Slide the large diameter of the boot over the outside of the CV race and locate the lip of the boot in the housing groove.
14. Slide the large retaining clamp over the boot.
15. Align the following items while latching:

15.1. | The wheel drive shaft outboard seal (1)

15.2. | The tri-pot housing

15.3. | The large seal retaining clip (2)

16. Using theSA9203C Axle Boot Clamp Installer (1), latch the large seal retaining clamp (2). Ensure that the latching tangs are fully engaged in the large seal clamp band.
17. Remove the wheel drive shaft from the bench vise.
18. Distribute the grease within the outer CV joint by plunging the joint back and fourth four to five times.
19. Inspect the outer CV joint and wheel drive shaft for smooth operation.

• | Hold the wheel drive shaft vertically, with the outer joint at the bottom.

• | Rotate the wheel drive shaft four or five times in a circular motion.

20. To install the wheel drive shaft to the vehicle, refer to Wheel Drive Shaft Replacement .