Special Tools

J 35566 Drive Shaft Boot Clamp Pliers

1. Remove the front wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Left Side for the left side. Refer to Front Wheel Drive Shaft Replacement - Right Side for the right side.
2. Remove the small boot clamp from the wheel drive shaft bar using side cutters and discard the clamp.

Note: Do not cut through the wheel drive shaft outboard boot or damage the sealing surface of the outer housing or the tripod bushing.

3. Remove the large boot clamp from the tripod joint with side cutters and discard the clamp.
4. Separate the wheel drive shaft outboard boot from the tripod bushing.
5. Slide the boot away from the joint along the wheel drive shaft.
6. Remove the housing from the tripod joint spider and the wheel drive shaft.

Note: The correct 60 degree offset relationship between the inner and outer tripod spiders must be maintained. Accurately reference mark the tripod spider position on the wheel drive shaft bar before disassembly.




7. Reference mark (1) the position of the tripod spider on the wheel drive shaft.
8. Remove the snap ring.



9. Using a brass drift and a hammer, remove the tripod spider (1) from the wheel drive shaft.
10. Remove the inboard joint boot from the drive shaft.
11. Inspect the following parts for damage or wear:

•	The wheel drive shaft outboard boot

•	The tripod joint spider assembly

•	The housing

•	The tripod bushing

•	The bearing

1. Position the beveled side of tripod axial spline toward the outboard joint.
2. Align the reference marks and install the tripod to the outboard joint shaft.
3. Install a new snap ring.
4. Pack the inboard joint and boot with grease.

Specification
145 g (5.1 oz)

5. Align the reference marks on the inboard joint shaft and outboard joint shaft.
6. Temporarily install the boot to the inboard joint.
7. Install the boots into the grooves on the drive shaft.

Caution: Refer to Fastener Caution in the Preface section.




8. Using J 35566 Clamp Pliers , crimp the small boot retaining clamp.



9. Using a suitable tool (1), measure the clearance of the boot clamp

Note: If the measured value exceeds the specified value, retighten the clamp

10. Inspect the clearance of the drive shaft joint boot clamp.

Specification
Clearance: 1.0 mm (0.0394 in)

11. Align the reference mark on the tripod spider and the wheel drive shaft bar.
12. Install the tripod spider to the wheel drive shaft bar, while compressing the barrel retaining ring with a flat-bladed tool.
13. Verify positive engagement of the tripod spider to the wheel drive shaft bar by grasping the tripod spider and attempting to pull free from the wheel drive shaft bar.




Note: Ensure the tripod bushing is flush with the face of the housing.

14. Place approximately half of the grease from the service kit in the wheel drive shaft outboard boot. Use the remainder of the grease to repack the housing.
15. Install the tripod bushing (5) to the housing (1).
16. Install the spring (2) to the tripod housing.

Use grease from the housing in order to retain the spring.

17. Install the guide (3) to the spring.

Use grease from the housing in order to retain the guide.

18. Position the larger new boot retaining clamp (4) on the wheel drive shaft outboard boot.
19. Slide the housing over the tripod joint spider assembly on the wheel drive shaft bar.



20. Slide the large diameter of the wheel drive shaft outboard boot (2), with the larger clamp (3) in place, over the outside of the tripod bushing and locate the lip of the seal in the groove.

Note: The wheel drive shaft outboard boot must not be dimpled, stretched out or out of shape in any way. If the wheel drive shaft outboard boot is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between the large seal opening and the tripod bushing in order to equalize the pressure. Shape the wheel drive shaft outboard boot properly by hand. Remove the tool.

21. Position the joint assembly at the proper vehicle dimension.



22. Align the following items while latching:

•	The wheel drive shaft outboard boot (1)

•	The tripod housing

•	The large boot retaining clamp (2)

23. Using J 35566 Clamp Pliers , crimp the large boot retaining clamp.



24. Using a suitable tool (1), measure the clearance of the boot clamp

Note: If the measured value exceeds the specified value, retighten the clamp

25. inspect the clearance of the drive shaft joint boot clamp.

Specification
Clearance: 1.0 mm (0.0394 in)

26. Rotate the outer tripod housing four or five times in order to distribute the grease throughout the tripod spider bearings.
27. Install the front wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Left Side for the left side. Refer to Front Wheel Drive Shaft Replacement - Right Side for the right side.