Raise and support vehicle. Remove wheel. Insert drift in brake rotor to prevent it from turning and remove axle shaft nut and washer. See Fig. 2. Remove bolt retaining stabilizer shaft link as necessary.
NOTE:The grease fitting for ball joint may need to be removed to gain access for Ball Joint Separator (J-36226).
Remove ball joint cotter pin and nut. Use Ball Joint Separator (J-36226) to free ball joint from knuckle. Separate ball joint by prying down on control arm. Use Front Hub Spindle Remover (J-28733-B) to force axle away from hub. See Fig. 3. Turn screw on remover until axle splines are loose of the bearing and hub assembly splines.
Pull knuckle assembly away from axle shaft. Move strut and steering knuckle assembly rearward. Using a slide hammer and Axle Shaft Remover (J-33008), remove FWD axle shaft from transaxle or intermediate shaft. See Fig. 5.
Fig. 5: Removing Axle Shaft From Transaxle
Disassembly (Tripod Type)
Cut tripod joint boot clamps and discard. See Fig. 1. DO NOT cut through boot, as it may damage sealing surface of outer housing and tripod bushing. Separate boot from tripod bushing and slide away from joint. Remove housing from spider and shaft.
Spread spacer ring, and slide spacer ring and spider further in on axle shaft. Remove shaft retainer ring from groove at end of axle shaft. Slide spider assembly off of axle shaft. Remove spacer ring and boot from axle.
WARNING:Wear safety glasses when using compressed air to dry parts.
Wash all parts (except boots) in solvent and dry with compressed air. Wash boots with soap and water. Inspect races for excessive wear and scoring. Inspect splined areas of shafts for wear, cracks and twists. Inspect tripod joint balls for pitting, cracking or scoring.
Reassembly (Tripod Type)
Install small boot clamp on neck of boot. DO NOT crimp clamp. Slide boot onto shaft, and position neck of boot in seal groove on axle shaft. Crimp retaining clamp with Boot Clamp Installer (J-41048) to specification. See TORQUE SPECIFICATIONS.
NOTE:Ensure chamfered side of spider faces end of axle shaft.
Install spacer ring past second groove on axle shaft. Install spider with chamfered side toward end of axle shaft. Slide spider against spacer ring on shaft. Install shaft retainer ring onto end of axle shaft. Slide spider up to retainer ring and seat spacer ring into second groove in axle shaft behind spider.
Pack CV joint housing with about one-half amount of grease supplied in rebuild kit. Apply remaining grease in boot. Install tripod bushing in tripod housing. Position large clamp onto CV boot. Slide housing over spider assembly. Slide large end of boot, with clamp in place, over outside of tripod bushing, and locate lip of boot in groove.
NOTE:Ensure boot, housing and clamp remain aligned while crimping.
Fig. 6: Measuring Inner CV Boot Length
Position joint assembly at 4.9" (125 mm) installed length. See Fig. 6. Ensuring boot is not dimpled, stretched or out of shape in any way, crimp large diameter retaining clamp with Boot Clamp Installer (J-35910) to specification. See TORQUE SPECIFICATIONS.
Tighten boot clamp to specification and ensure clamp ear gap is.102" (2.60 mm) or less. See Fig. 8. If ear gap is larger than specification, continue tightening clamp for proper measurement. See TORQUE SPECIFICATIONS.
Disassembly (Rzeppa Type Outer CV Joints)
Place axle shaft in soft-jaw vise with protective jaws. Cut and remove boot clamps. Slide boot away from outer CV joint assembly. Wipe grease from the face of the outer CV joint inner race. Using snap ring pliers, spread CV joint inner race retaining ring and pull CV joint and housing assembly off of axle shaft. Remove boot (if replacing).
Place CV joint in soft-jaw vise with protective jaws. Using a brass drift and hammer, gently tap on cage until cage is tilted enough to remove the first ball. See Fig. 7. Repeat procedure for the remaining balls. Pivot cage and inner race. Align cage windows with lands of outer race and remove inner race and cage. Remove and discard inner race retaining ring. See Fig. 7.
Fig. 7: Disassembling Outer CV Joint (Rzeppa Type)
Remove grease and any contaminates from all parts. Inspect boot, inner race, cage, outer race, axle shaft and balls for damage or wear.
Reassembly (Rzeppa Type Outer CV Joints)
Apply light coat of grease on all mating surfaces. Install small boot clamp and boot on axle shaft. Use Small Swage Tool (J-41048) and torque wrench to install small boot clamp. Tighten small boot clamp to specification. See TORQUE SPECIFICATIONS.
NOTE:Ensure retaining ring side of inner race faces inward on axle shaft.
To reassemble inner race, cage and balls, reverse disassemble procedure. See Fig. 7. Ensure retaining ring side of inner race faces inward on axle shaft. Pack CV joint with one-half amount of grease supplied in the rebuild kit. Spread remaining grease evenly in boot.
NOTE:A NEW CV joint inner race retaining ring MUST be used during reassembly.
Install NEW retaining ring into CV joint inner race. Align splines of outer CV joint inner race and axle shaft and slide CV joint assembly onto axle shaft. Ensure inner race retaining ring seats in groove on axle shaft. Position large end of boot over housing, and install large boot clamp.
Use Boot Clamp Installer (J-35910) and torque wrench to install large boot clamp. Tighten boot clamp to specification and ensure clamp ear gap is.102" (2.60 mm) or less. See Fig. 8. If ear gap is larger than specification, continue tightening clamp for proper measurement. See TORQUE SPECIFICATIONS.
Fig. 8: Checking Air Gap On Large CV Boot Clamp Ear
To install, reverse removal procedure. Use NEW axle hub nut. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS.
Friday, April 16th, 2010 AT 3:49 AM