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Axle Shaft Outer Joint & Seal: Reassembly

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  1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. Put a light coat of the recommended grease on the inner and the outer race grooves. See Figure.
  2. Hold the inner race at 90 degrees to the centerline of the cage. Align the lands of the inner race with the windows of the cage. Insert the inner race into the cage, by rotating the inner race downward. See Figure.
  3. Insert the cage and inner race into the outer race. Place a brass drift against the CV joint cage. Tap gently on the brass drift with a hammer in order to tilt the cage. Install the first chrome alloy ball when the CV joint cage tilts. Tilt the CV joint cage in the opposite direction to install the opposing chrome alloy ball. Repeat this process in order to install all six of the balls.
  4. Pack the CV joint boot 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. Place the new small boot clamp onto the CV joint seal. Slide the CV joint boot onto the halfshaft bar. Position the small end of the CV joint boot into the joint boot groove on the halfshaft bar.
  5. Secure the small boot clamp using Drive Axle Seal Clamp Pliers (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp to specifications. See TORQUE SPECIFICATIONS . See Figure. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Gap dimension is .085" (2.15 mm).
  6. Pinch the new swage ring slightly by hand to distort it into an oval shape. Slide the distorted swage ring over the large diameter of the boot. Pull on the CV joint to verify engagement. Slide the large diameter of the CV joint boot, with the large swage ring in place, over the outside edge of the CV joint outer race.
  7. Clamp the CV joint boot tightly to the CV joint outer race with the large swage ring, using the following procedure:
    1. Mount the base of Drive Axle Clamp Swage Tool in a vise.
    2. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of Drive Axle Clamp Swage Tool.
    Align the CV joint boot, the CV joint assembly and the swage ring during this procedure.
  8. Install the top half of Drive Axle Clamp Swage Tool onto the lower half of the tool, over the CV joint boot and the CV joint assembly. Align the swage ring and the swage ring clamp. Insert the bolts into Drive Axle Clamp Swage Tool. Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of Drive Axle Clamp Swage Tool touch the bottom half of the tool. Loosen the bolts and remove the halfshaft assembly from Drive Axle Clamp Swage Tool.
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