Tools Required

J 8059 Snap Ring Pliers

1. Place the drive axle in a vise.
2. Place protective covers over the vise jaws.
3. Remove the seal clamp protectors (2) (if used) from the outer CV joint (1).
4. Cut the clamps (3) from the seal with a pair of side cutters. Use a hand grinder to cut through the swage ring. Do not damage the outer race.
5. Slide the seal down the drive axle and away from the CV joint outer race (1).
6. Wipe all grease away from the face of the CV joint.



7. Find the drive axle retaining snap ring (3), which is located in the inner race (2).
8. Spread the snap ring ears apart using J 8059 (or equivalent).
9. Pull the CV joint from the drive axle (4). Discard the old seal.



10. Use the following procedure to disassemble the CV joint.

10.1.

Place a brass drift against the cage (1).

10.2.

Tap gently on the brass drift in order to tilt the cage.

10.3.

Remove the first ball (2) when the cage tilts.

10.4.

Repeat the previous step to remove all of the balls.




11. Pivot the cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2).
12. Lift out the cage (4) and the inner race.



13. Remove the inner race from the cage by rotating the inner race upward.
14. Thoroughly degrease all of the CV joint parts.
15. Check the outer CV joint assembly for unusual wear, cracks, or other damage. Replace any damaged parts.
16. Clean the axle shaft. Use a wire brush to remove any rust in the seal mounting area (grooves).

1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the joint assembly if necessary.
2. Put a light coat of the recommended grease on the inner and the outer race grooves.
3. Insert the inner race into the cage by rotating the inner race downward.
4. Hold the inner race (1) at 90 degrees to the centerline of the cage.



5. Align the lands of the inner race (2) with the windows of the cage (3).
6. Insert the inner race into the cage, by rotating the inner race downward.
7. Insert the cage (4) and inner race into the outer race (1).



8. Place a brass drift against the cage (1).
9. Tap gently on the brass drift in order to tilt the cage (1).
10. Install the first ball (2) when the cage tilts.
11. Repeat previous step to reinstall all of the balls.

Tools Required

1. Pack the CV joint seal and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
2. Place the new small swage clamp (2) onto the CV joint seal (1).
3. Place the large retaining clamp on the seal (1).
4. Compress the CV joint seal (1). While the CV joint seal is compressed, slide the CV joint seal onto the axle shaft.
5. Position the small end of the CV joint seal (1) into the joint seal groove (3) on the axle shaft.



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



7. Align the swage clamp (2) within the J 41048 .



8. Place the top half of the J 41048 on the bottom half.
9. Check to make sure there are no pinch points on the seal before proceeding with procedures.
10. Insert the bolts (2). Tighten the bolts (2) by hand until snug.
11. Align the following items:

•

The seal

•	The housing

•	The swage clamp

Tighten
Each bolt 180 degrees at a time, using a ratchet wrench. Alternate between each bolt until both sides are bottomed.

12. Loosen the bolts. Separate the dies.
13. Check the swage clamp for any "lip" deformities. If the deformities exist, place the swage clamp back into theJ 41048 . Ensure the swage clamp covers the whole swaging area. Re-swage the swage clamp.




Important: Ensure that the retaining ring side of the CV joint inner race faces the axle shaft (1) before installation.

14. Place the retaining snap ring into the CV joint inner race.
15. Slide the CV joint (2) onto the axle shaft (1). The retaining snap ring inside of the inner race engages in the axle shaft groove with a click when the CV joint is in the proper position.
16. Pull on the CV joint (2) to verify engagement.



17. Slide the large diameter of the CV joint seal (1), with the large retaining ring (2) in place, over the outside edge of the CV joint outer race (3).
18. Position the lip of the CV joint seal (1) into the groove on the CV joint outer race (3).
19. Manipulate the CV joint seal (1) to remove any excess air.



20. Secure the large retaining clamp (1) this replaces the swage ring and the seal to the housing with the J 35910 (or equivalent), a breaker bar (3), and a torque wrench (2).

Tighten
Torque the large retaining clamp (1) to 176 N·m (130 lb ft).

21. Check the gap dimension on the clamp ear.
22. Install the seal clamp protectors (if used) over the large retaining clamp.