Tools Required

Notice: With the removal of the wheel drive shaft for any reason, the transmission sealing surface (the tripot male/female shank of the joint) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotational motion only. Do not clean with an oscillating motion. Transmission fluid may be used to clean off any remaining debris and the joint wiped dry before installation. Corrosion on the joint sealing surface may damage the transmission seals and cause a fluid leak.

1. Use a hand grinder in order to cut through the swage ring.
2. Remove the large seal retaining clamp from the tripot joint with side cutter.
3. Dispose of the large seal retaining clamp.

Notice: 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.

4. Separate the halfshaft inboard seal (4) from the trilobal tripot bushing (3) at the large diameter.
5. Slide the seal away from the joint along the halfshaft bar.
6. Remove the housing (1) from the tripot joint spider (2) and the halfshaft bar.
7. Remove and discard the trilobal tripot bushing (3) from the housing (1).



8. Remove the following items:

•	The spacer ring (1) using J 8059

•	The spider assembly (2)

•	The spacer ring (3) using J 8059

•	The inboard boot (4)

9. Discard both rings and the inboard boot.
10. Clean the halfshaft bar (5). Use a wire brush to remove any rust in the boot mounting area.
11. Clean the following items with cleaning solvent:

•	The tripot balls

•	The needle rollers

•	The housing

12. Remove all traces of old grease and any contaminates. Dry all parts.
13. Inspect the following parts for damage or wear:

•	The tripot joint spider assembly

•	The housing

•	The needle rollers

1. Place the new small swage ring (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the small swage ring (2) onto the halfshaft bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.



3. Mount J 41048 in a vise and proceed as follows:

3.1.	Position the inboard end (1) of the halfshaft assembly in tool J 41048 .

3.2.	Align the top of seal neck on the bottom die using the indicator.

3.3.	Place the top half of the J 41048 on the lower half of the J 41048 .

3.4.	Before proceeding, ensure there are no pinch points on the halfshaft inboard seal. This could cause damage to the halfshaft inboard seal.

3.5.	Insert the bolts (2).

3.6.	Tighten the bolts by hand until snug.

Notice: Refer to Fastener Notice in the Preface section.




4. Align the following items:

•	The halfshaft inboard seal (1)

•	The halfshaft bar

•	The swage ring (2)

Tighten
Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.




5. Install the spacer ring (2) on the halfshaft bar (1) in the groove using J 8059 .



6. Slide the tripot joint spider assembly (4) toward the spacer ring (1) as far as it will go on the halfshaft bar.
7. Install the spacer ring (2) in the groove of the halfshaft bar.



8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the remainder of the grease to repack the housing.

Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

9. Install the new trilobal tripot bushing (3) to housing (1).
10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.



12. Slide the large diameter of the halfshaft inboard seal (2), with the larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
13. Position the joint assembly at the proper vehicle dimension.

•	For 4.0L and 3.8L supercharged engine vehicles, dimension a = 111 mm  (4.37 in).

•	For 3.8L engine vehicles, dimension a = 95 mm (3.75 in).

14. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool.



15. Align the following items while latching:

•	The halfshaft inboard seal

•	The tripot housing (2)

•	The large seal retaining clamp (3)

Tighten
Crimp the seal retaining clamp with J 35910 to 176 N·m (130 lb ft). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary.

16. Check the gap dimension (a) on the clamp ear. If gap dimension is larger than shown, continue tightening until gap dimension of 2.60  mm (0.102 in) is reached.