Orlando

Front Wheel Drive Shaft Inner Joint and Boot Replacement - with Tripod Joint

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Remove the left or right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Left Side or Front Wheel Drive Shaft Replacement - Right Side .



2. Remove the large seal retaining clamp from the CV joint with a side cutter. DISCARD the seal retaining clamp.

Warning: Use of eye goggles is necessary to prevent personal injury.

3. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp.
4. Separate the halfshaft outboard seal from CV joint outer race (1) at large diameter.
5. Slide the seal (4) away from joint along halfshaft bar (5).
6. Wipe the grease from the face of the CV joint inner race (2).
7. Spread the ears on the race retaining ring (3) with the GE-396 pliers (6).
8. Remove the CV joint assembly (1) from the halfshaft bar (5).
9. Remove the halfshaft outboard seal (4) from the halfshaft bar (5).
10. DISCARD the old outboard seal.
11. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.

•	The inner and outer race assemblies

•	The CV joint cage

•	The chrome alloy balls

12. Dry all the parts.
13. Check the CV joint assembly for the following items:

•	Unusual wear

•

Cracks

•

Damage

1. Replace and DISCARD the halfshaft bar.

Note: Place a towel in the vise before inserting the halfshaft.

2. Mount the NEW halfshaft into a vice.



3. Install the NEW small eared clamp (2) on the neck of the outboard seal (1). Do not crimp.
4. Slide the outboard seal (1) onto the halfshaft bar and position the neck of the outboard seal (1) in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove (3).

Caution: Refer to Fastener Caution in the Preface section.




5. Crimp the eared clamp, using the CH-804 tensioner (1) and a torque wrench. Tighten the eared clamp to 25 N·m (18 lb ft).
6. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.



7. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the halfshaft bar.




Note: The outboard seal (1) must not be dimpled, stretched or out of shape in any way. If the outboard seal (1) is not shaped correctly, equalize the pressure in the outboard seal (1) and shape the seal properly by hand.

8. Slide large diameter of the outboard seal (1) with the large seal retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the seal lip in the groove on the CV joint outer race.



9. Crimp the seal retaining clamp (1) using the CH-804 tensioner to 25 N·m (18 lb ft).
10. Install the left or right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Left Side or Front Wheel Drive Shaft Replacement - Right Side .