Astro, Safari 1997-2005

CV-Joints

Print

Overhaul



Inner CV-Joint & Boot
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove front wheel.
  4.  
  5. Remove halfshaft and place it in a vise.
  6.  
  7. Remove snapring from the stub shaft and discard it.
  8.  
  9. Remove small CV-joint boot clamp, cut and discard it.
  10.  
  11. Remove large CV-joint boot clamp, cut and discard it.
  12.  
  13. Remove CV-joint boot by sliding it away from the Tri-Pod joint.
  14.  
  15. Install a Stub Shaft Removal tool J-38868-A to the stub shaft snapring groove.
  16.  
  17. Using a slide hammer puller, press the stub shaft from the Tri-Pod housing.
  18.  
  19. Remove Tri-Pod housing from the Tri-Pod spider.
  20.  
  21. Remove inboard spacer ring and slide it rearward on the shaft using Snapring Pliers tool J-8059.
  22.  
  23. Remove outboard retaining ring using Snapring Pliers tool J-8059 and discard it.
  24.  
  25. Remove Tri-Pod joint spider assembly.
  26.  
  27. Remove inboard spacer ring and discard it.
  28.  
  29. Remove CV-joint boot.
  30.  
  31. Remove trilobal Tri-Pod bushing from the housing.
  32.  
  33. Thoroughly clean and inspect all parts.
  34.  

To install:

  1. Install new snapring onto the stub shaft.
  2.  
  3. Install small boot clamp.
  4.  
  5. Install CV-joint boot.
  6.  
  7. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm).
  8.  
  9. Install inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059, past the 2nd groove.
  10.  
  11. Install Tri-Pod joint spider assembly onto the shaft until it passes the 2nd groove.
  12.  
  13. Install outboard retaining ring into the axle shaft groove using Snapring Pliers tool J-8059.
  14.  
  15. Install Tri-Pod joint spider assembly, slide it against the outboard retaining ring.
  16.  
  17. Install inboard spacer ring, seat it in the groove.
  18.  
  19. Apply 1 / 2 kit grease into the boot.
  20.  
  21. Apply 1 / 2 kit grease into the Tri-Pod housing.
  22.  
  23. Install trilobal tip-pot bushing flush with the Tri-Pod housing face.
  24.  
  25. Install new large seal clamp onto the CV-joint boot.
  26.  
  27. Install Tri-Pod housing, slide it over the Tri-Pod joint spider assembly.
  28.  
  29. Install CV-joint boot/clamp, slide it into place, over the trilobal Tri-Pod bushing with the seal lip in the groove.
    NOTE
    Make sure the boot lies flat against the trilobal bushing.

  30.  
  31. Position the CV-joint boot so it measures 4.9 in. (125mm).
  32.  
  33. Using the Crimp tool J-35566, latch the large CV-joint boot clamp.
  34.  
  35. Install the halfshaft and the front wheel.
  36.  

Outer CV-Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove front wheel.
  4.  
  5. Remove halfshaft and position it in a vise.
  6.  
  7. Remove large CV-joint boot clamp and discard it.
  8.  
  9. Remove small CV-joint boot clamp and discard it.
  10.  
  11. Remove CV-joint boot and slide it back on the shaft.
  12.  
  13. Remove outer race from the halfshaft, by spreading the outer race-to-halfshaft retaining ring, using Snapring Pliers J-8059.
  14.  
  15. Remove retaining ring from the halfshaft and discard it.
  16.  
  17. CV-joint boot from the halfshaft and discard it, if damaged.
  18.  
  19. Disassemble the chrome alloy balls from the CV-joint cage as follows:
    1. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage.
    2.  
    3. Remove the 1st chrome alloy ball from the cage.
    4.  
    5. Tilt the cage in the opposite direction.
    6.  
    7. Remove the opposite chrome alloy ball.
    8.  
    9. Repeat the procedure until all 6 balls are removed.
    10.  

  20.  
  21. Disassemble the CV-joint cage and inner race as follows:
    1. Pivot the cage and race 90 degrees to the center line of the outer race.
    2.  
    3. Align the cage windows with outer race lands.
    4.  
    5. Remove the cage from the outer race.
    6.  
    7. Rotate the inner race upward and remove it from the cage.
    8.  

  22.  
  23. Thoroughly clean and inspect all parts.
  24.  

To install:

  1. Lubricate the parts with a light coat of grease.
  2.  
  3. Assemble the CV-joint cage and inner race, as follows:
    1. Rotate the inner race 90 degrees to the cage centerline.
    2.  
    3. Align the cage windows with inner race lands.
    4.  
    5. Insert the inner race into the cage by rotating the inner race downward.
    6.  
    7. Insert the cage/inner race into the outer race.
    8.  

  4.  
  5. Assemble the chrome alloy balls into the CV-joint cage, as follows:
    1. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage.
    2.  
    3. Insert the 1st chrome alloy ball into the cage.
    4.  
    5. Tilt the cage in the opposite direction.
    6.  
    7. Insert the opposite chrome alloy ball.
    8.  
    9. Repeat the procedure until all 6 balls are inserted.
    10.  

  6.  
  7. Install 1 / 2 kit grease into the CV-joint.
  8.  
  9. Install small ring clamp on the CV boot.
  10.  
  11. Install new retaining ring on the halfshaft.
  12.  
  13. Install large ring clamp on the CV boot.
  14.  
  15. Install outer race assembly onto the halfshaft until the ring engages the halfshaft groove.
  16.  
  17. Slide the small end of the CV-joint boot/clamp into place, with the seal lip in the halfshaft groove
    NOTE
    Make sure the boot lies flat against the halfshaft.

  18.  
  19. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm).
  20.  
  21. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.
  22.  
  23. Install 1 / 2 kit grease into the CV-joint boot.
  24.  
  25. Measure approximately 0.687 in. (17.5mm) up from the bottom edge of the outer CV-joint assembly.
  26.  
  27. Slide the large end of the CV boot/clamp into place, with the seal lip in place over the outer race.
    NOTE
    Make sure the boot lies flat against the outer race.

  28.  
  29. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. lbs. (176 Nm).
  30.  
  31. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  32.  
  33. Install the halfshaft and the front wheel.

    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint Assembly

  34.  

 
label.common.footer.alt.autozoneLogo