Rear

Wheel Drive Shaft Outer Joint and Seal Replacement - Rear

^ Tools Required
- J 35566 Drive Axle Seal Clamp Pliers
- J 42572 Drive Shaft Seal Clamp Pliers

Disassembly Procedure





1. Remove the small seal clamp from the wheel drive shaft bar using side cutters and discard the clamp.

Important: Do not cut through the wheel drive shaft outboard seal and damage sealing surface of the outer housing and the trilobal tri-pot bushing.

2. Remove the large seal clamp (4) from the tri-pot joint with side cutters and discard the clamp.
3. Separate the wheel drive shaft outboard seal from the trilobal tri-pot bushing (5).
4. Slide the seal away from the joint along the wheel drive shaft bar.
5. Remove the housing from the tri-pot joint spider and the wheel drive shaft bar.





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

6. Reference mark the position of the tri-pot spider (1) on the wheel drive shaft bar (2).
7. Using a brass drift and hammer, carefully tap around the tri-pot spider face in order to compress the barrel retaining ring on the, wheel drive shaft bar.
8. Remove the tri-pot spider from the wheel drive shaft bar (2).
9. Remove and discard the barrel retaining ring from the wheel drive shaft bar.
10. Remove the joint seal from the wheel drive shaft bar.
11. Inspect the following parts for damage or wear:
^ The wheel drive shaft outboard seal
^ The tri-pot joint spider assembly (1)
^ The housing
^ The trilobal tri-pot bushing

Assembly Procedure





1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the small seal clamp (2) onto the wheel drive shaft bar.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the wheel drive shaft bar.

Notice: Refer to Fastener Notice in Service Precautions.

3. Using the J 42572, crimp the small seal retaining clamp.
^ Tighten the clamp to 136 Nm (100 ft. lbs.).





4. Install a new barrel retaining ring to the wheel drive shaft bar.

Important: The proper 60 degree offset relationship between the inner and outer tri-pot spiders must be maintained.

5. Align the reference mark on the tri-pot spider and the wheel drive shaft bar.

Important: Ensure that the beveled edge of the tri-pot spider faces the wheel drive shaft bar during reassembly.

6. Install the tri-pot spider to the wheel drive shaft bar, while compressing the barrel retaining ring with a flat-bladed tool.
7. Verify positive engagement of the tri-pot spider to the wheel drive shaft bar by grasping the tri-pot spider and attempting to pull free from the wheel drive shaft bar.





Important: Ensure the trilobal tri-pot bushing is flush with the face of the housing.

8. Place approximately half of the grease from the service kit in the wheel drive shaft outboard seal. Use the remainder of the grease to repack the housing.
9. Install the trilobal tri-pot bushing (5) to the housing (1).
10. Install the spring (2) to the tri-pot housing.
Use grease from the housing in order to retain the spring.
11. Install the guide (3) to the spring.
Use grease from the housing in order to retain the guide.
12. Position the larger new seal retaining clamp (4) on the wheel drive shaft outboard seal.
13. Slide the housing over the tri-pot joint spider assembly on the wheel drive shaft bar.





14. Slide the large diameter of the wheel drive shaft outboard seal (2), with the larger clamp (3) in place, over the outside of the trilobal tri-pot bushing and locate the lip of the seal in the groove.

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

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





16. Align the following items while latching:
^ The wheel drive shaft outboard seal (1)
^ The tri-pot housing
^ The large seal retaining clamp (2)
17. Using the J 35566, latch the large seal retaining clamp. Ensure that the latching tangs are fully engaged in the large seal clamp band.
18. Rotate the outer tri-pot housing four or five times in order to distribute the grease throughout the tri-pot spider bearings.