Disassembly and assembly

Inner c/v joint

DISASSEMBLY

(1) Remove the axle driveshaft.

(2) Place the inner C/V joint housing in a vise.

(3) Remove the inner boot retaining clamps. Pull the inner boot back onto the interconnecting shaft.

Discard the retaining clamps.

(4) Pull the tripod and shaft straight out from the inner C/V joint housing.

(5) Remove the snap retaining ring from the groove behind the tripod (Fig. 9). Slide the tripod toward the center of the shaft. Remove the C-clip on the outer end of the shaft (Fig. 10).

(6) Remove the tripod from the shaft. Replace the boot, if necessary.

(7) Remove the lubricant from the interior of the housing and from the tripod.

(8) Inspect the needle bearing raceways in the housing and tripod components for excessive wear and damage. Replace the tripod as a unit only if necessary.

ASSEMBLY

(1) Slide the boot down enough for work access.

(2) Install the snap ring past the ring groove (toward the center of the shaft). Slide the tripod onto the end of the interconnecting shaft. Be sure the chamfered end of the tripod is adjacent to the C-clip retaining ring groove (Fig. 10).

Fig. 9 Snap Retaining Ring Removal

1 - SNAP RING

2 - TRIPOD JOINT

3 - SNAP RING PLIERS

Fig. 10 C-Clip Removal/Installation

1 - SNAP RING

2 - CHAMFERED EDGE

3 - C-CLIP GROOVE

4 - C-CLIP

5 - TRIPOD

(3) Install the C-clip in the groove. Slide the tripod out against the clip. Install the snap ring in the inner groove. Be sure the snap ring and C-clip are seated.

(4) Apply the required quantity of lubricant to the housing and boot. Coat the interior of the joint housing and the tripod.

(5) Insert and seat the tripod and shaft in the housing.

(6) Position the large-diameter end of the inner C/V joint boot over the edge of the housing. Insert the lip of the boot into the locating groove at the edge of the housing (Fig. 11).

Fig. 11 Inner C/V Joint Boot

1 - SMALL CLAMP

2 - SEALING BOOT

3 - LARGE CLAMP

4 - INTERCONNECTING SHAFT

5 - INNER TRIPOD JOINT

(7) Insert the small lip into the locating groove in the interconnecting shaft.

(8) Retain the small-diameter of the boot on the shaft with a ladder-type clamp in the boot groove.

Verify that the boot and lip are properly positioned on the intermediate shaft. Position the clamp locating tabs in the slots and tighten the clamp.

(9) Compress the clamp bridge with Remover/Installer C-4124. Squeeze the tool handles to complete the tightening of the clamp (Fig. 12). Care must be exercised when using the tool to avoid cutting through the clamp bridge or damaging the boot.

Fig. 12 Compressing Clamp Bridge

1 - TOOL C-4124

2 - SLINGER

(10) Position the large-diameter end of the boot on the C/V joint housing.

(11) After the inner joint boot small clamp is installed, the inboard hub must be set to a service build length.

(a) Compress the inner hub down the connector shaft.

(b) Use a small blunt drift between the large end and the boot seal to relieve the pressure.

(c) The distance edge of the lip to the edge of the flange should be 181.00 mm (7.13 in.). This will eliminate excess air that can cause a ballooning affect and possibly cause damage to the boot.

(12) Verify that the boot is not twisted and that it is correctly positioned on the housing.

(13) Install the large ladder clamp on the boot and secure as done with the small ladder clamp (Fig. 12).

Outer c/v joint

If the outer C/V joint is excessively worn, replace the entire C/V joint and boot.

DISASSEMBLY

(1) Remove retaining clamps from the outer C/V joint and discard. Slide the boot off the outer joint and down the shaft.

(2) Remove the lubricant to expose the outer C/V joint components (Fig. 13).

Fig. 13 Outer C/V Joint Components

1 - RZEPPA JOINT HOUSING (OUTER)

2 - CLAMP

3 - BEARING HUB

4 - BEARING CAGE

5 - SHAFT

6 - CLAMP

7 - BOOT

8 - SNAP RING

9 - BALLS (6)

10 - WASHER

11 - HUB NUT

12 - NUT LOCK

13 - SPRING WASHER

14 - COTTER PIN

(3) Clamp the shaft in a vise (with soft jaws). Support the outer C/V joint.

(4) Use snap ring pliers to release the clip from the groove.

(5) Slide the outer C/V joint from the shaft (Fig.

14).

Fig. 14 Outer C/V Joint Removal

1 - SNAP RING

2 - SNAP RING GROOVE

3 - SNAP RING PLIERS

(6) Remove the slinger, if damaged, from the outer C/V joint. Use a brass drift and a hammer. Tap slinger ring off C/V joint and discard.

(7) Remove the old lubricant. Apply installation alignment marks on the bearing hub, bearing cage and housing with dabs of paint (Fig. 15).

Fig. 15 Ball Access

1 - INSTALLATION ALIGNMENT MARKS

2 - BEARING HUB

3 - BEARING CAGE

4 - CV JOINT HOUSING (OUTER)

(8) Clamp the outer C/V joint in a vertical position.

Place the stub shaft in a soft-jawed vise.

(9) Press down on one side of the bearing cage/hub to tilt the cage. This will provide access to a ball at the opposite side of the cage. If the C/V joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift.

(10) Remove the ball from the bearing cage (Fig.

16). If necessary, a small pry bar can be used to pry the ball loose from the cage.

Fig. 16 Ball Removal

1 - CV JOINT HOUSING (OUTER)

2 - BEARING HUB (UP)

3 - BEARING CAGE (UP)

4 - BALL

(11) Repeat the step above until all six balls are removed from the bearing cage.

(12) Tilt the bearing cage and hub to a vertical position. Remove the cage from the housing. Pull cage upward and away from the housing (Fig. 17).

(13) Turn the bearing hub 90 from the bearing cage. Align one pair of the hub lands with the cage windows. Raise and insert one of the lands into the adjacent cage window. Remove the bearing hub by rolling it out of the cage (Fig. 18).

Fig. 17 Bearing Cage & Hub Removal

1 - CV JOINT HOUSING (OUTER)

2 - BALL RACE

3 - BEARING CAGE WINDOW

Fig. 18 Bearing Hub Removal

ASSEMBLY

(1) Lightly apply lubricating oil to all the outer C/V joint components before assembling them.

(2) Align the bearing hub, cage and housing (Fig.

15) according to the alignment reference marks.

(3) Insert one of the bearing hub lands into a bearing cage window (Fig. 18). Roll the hub into the cage (Fig. 19). Rotate the bearing hub 90 to complete the installation (Fig. 20).

Fig. 19 Bearing Hub Installation

1 - BEARING HUB

2 - BEARING CAGE

Fig. 20 Assembled Bearing Cage & Hub

1 - CAGE WINDOWS

2 - CIRCLIP RETAINER

(4) Insert bearing cage/hub into the housing (Fig.

21). Rotate the cage/hub 90 to complete the installation (Fig. 22).

(5) Apply the lubricant included with the replacement boot to the ball raceways. Spread the lubricant equally between all the raceways. One packet of lubricant is sufficient to lubricate the complete C/V joint.

(6) Tilt the bearing hub and cage and install the balls in the raceways (Fig. 23).

Fig. 21 Bearing Cage & Hub Installation

1 - BALL RACE

2 - BEARING CAGE WINDOW

3 - CV JOINT HOUSING (OUTER)

Fig. 22 Bearing Cage & Hub Installed In Housing

1 - CV JOINT HOUSING (OUTER)

2 - BEARING HUB LARGE COUNTERBORE OUTWARD

3 - BOOT RETAINING SHOULDER

4 - BEARING HUB SMALL COUNTERBORE INWARD

5 - SLINGER

(7) Apply a small amount of lubricant to inner diameter of slinger. Place slinger squarely on the outer C/V joint. Use installer tool L-4518-1 from tool set L-4518 and hammer slinger onto joint until it seats (Fig. 24).

CAUTION: Prevent damage to the slinger after installation or a when a replacement outer C/V joint is installed.

Fig. 23 Ball Installation In Raceway

1 - CV JOINT HOUSING (OUTER)

2 - BEARING HUB (UP)

3 - BEARING CAGE (UP)

4 - BALL

Fig. 24 Slinger Installation

1 - HAMMER

2 - OUTER C.V. JOINT

3 - SLINGER

4 - SPECIAL TOOL L-4518-1

(8) Position the small-diameter end of the replacement boot on the interconnecting shaft. Retain the boot with a replacement clamp.

(9) Apply the required amount of lubricant to the outer C/V joint and boot.

(10) Align the shaft splines to the outer C/V joint splines. Push the outer C/V joint until the snap ring seats in the groove (Fig. 25).

Fig. 25 Outer C/V Joint Installation

1 - SNAP RING

2 - SHAFT TAPER

3 - SNAP RING GROOVE

4 - BEARING HUB

(11) Ensure that the snap ring is properly seated in the housing. Pull the outer C/V joint from the interconnecting shaft to test.

(12) Place the large-diameter end of the replacement boot over the edge of the C/V joint housing.

Ensure that the boot is not twisted.

(13) Retain the boot on the housing with a replacement retaining clamps.