Avalanche, Sierra, Silverado, C&K Series, 1999-2005

CV-Joints

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Overhaul



Inner CV-Joint & Boot

NOTE
With removal of the halfshaft for any reason, the transmission sealing surface (the tripod male/female shank of the halfshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent. Transmission fluid may be used to clean off any remaining debris. The surface should be wiped dry and the halfshaft reinstalled free of any buildup.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Use a hand grinder in order to cut through the swage ring.
  4.  
  5. Remove the tripod housing from the halfshaft. Wipe the grease off of the tripod assembly roller bearings and the tripod housing. Thoroughly degrease the tripod housing. Allow the tripod housing to dry prior to assembly.
    NOTE
    Handle the tripod spider assembly with care. Tripod balls and needle rollers may separate from the spider trunnion if the tripod balls and needle rollers are not handled carefully.

  6.  
  7. Use side cutters to cut away the small boot clamp.
  8.  
  9. Compress the tripod boot up the halfshaft away from the tripod spider assembly toward the outboard (CV joint assembly) end of the halfshaft.
  10.  
  11. Spread the spider spacer ring with tool J8059, or equivalent.
  12.  
  13. Remove the following items from the halfshaft bar:
    1. The spacer ring.
    2.  
    3. The spider assembly.
    4.  
    5. The tripod boot.
    6.  

  14.  
  15. Clean the halfshaft bar. Use a wire brush in order to remove any rust in the boot mounting area (grooves).

    Click image to see an enlarged view

    Fig. Assembled joint measurement-15 Series Pickups

  16.  
  17. Inspect the needle rollers, needle bearings, and trunnion. Check the tripod housing for unusual wear, cracks, or other damage. Replace any damaged parts.

    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint assembly

  18.  

To assemble:

  1. Place the new small boot clamp onto the small end of the joint boot.
  2.  
  3. Compress the joint boot and small boot clamp onto the halfshaft bar.
  4.  
  5. Position the small end of the joint boot into the joint boot groove on the halfshaft bar.
  6.  
  7. Secure the small boot clamp with tool J35910, or equivalent, a breaker bar, and a torque wrench. Tighten the small boot clamp (1) to 100 ft. lbs. (136 Nm).
  8.  
  9. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
    NOTE
    Assemble the CV joint with the convolute retainer in the correct position, as illustrated.

  10.  
  11. Install the convolute retainer over the inboard joint boot, being sure to capture three convolutions.
  12.  
  13. Install the tripod spider assembly onto the halfshaft bar with the counterbore towards the end of the halfshaft bar.
  14.  
  15. Install the spacer ring in the groove at the end of the halfshaft bar.
  16.  
  17. Push the spider assembly back toward the end of the halfshaft bar until the spacer ring is covered by the spider assembly counterbore.
  18.  
  19. Pack the tripod boot and the tripod housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
  20.  
  21. Reassemble the tripod housing and the tripod boot using the following procedure:
    1. Pinch the swage ring slightly by hand in order to distort it into an oval shape.
    2.  
    3. Slide the distorted swage ring over the large diameter of the boot.
    4.  
    5. Place the tripod housing over the spider assembly.
    6.  
    7. Install the boot onto the tripod housing.
    8.  
    9. Align the tripod boot with the swage ring in place, over the flat area on the tripod housing.
    10.  

  22.  
  23. Mount tool J36652 in a vise. Install the bottom half of the split-plate swage clamp. For K15 models, use tool J36652-98. For K25 models, use tool J36652-1.
  24.  
  25. Check the inboard stroke position. Use measurement A for the K15 models. Use measurement B for the K25 models.
  26.  
  27. Position the inboard end (tripod end) of the halfshaft assembly in tool J36652. Install the top half of the proper size tool on the lower half of the tool. For K15 models, use tool J36652-98. For K25 models, use tool J36652-1.
  28.  
  29. Align the swage ring and the swage ring clamp. Insert the bolts. Hand tighten the bolts in tool J36652 until the bolts are snug.
  30.  
  31. Align the following during this procedure:
    1. The tripod boot.
    2.  
    3. The housing.
    4.  
    5. The swage ring. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J36652 touch the bottom half of the tool.
    6.  

  32.  
  33. Loosen the bolts and remove the halfshaft assembly from J36652.
  34.  
  35. Remove the convolute retainer from the boot.
  36.  

Tripod Joint
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft and place it in a vise
     
    Snapring from the stub shaft and discard it
     
    Small CV-joint boot clamp, cut and discard it
     
    Large CV-joint boot clamp, cut and discard it
     
    CV-joint boot by sliding it away from the tri-pot joint
     

  4.  
  5. Install a Stub Shaft Removal tool J-38868-A to the stub shaft snapring groove.
  6.  
  7. Using a slide hammer puller, press the stub shaft from the tri-pot housing.
  8.  
  9. Remove or disconnect the following:

    Tri-pot housing from the tri-pot spider
     
    Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059
     
    Outboard retaining ring using Snapring Pliers tool J-8059 and discard it
     
    Tri-pot joint spider assembly
     
    Inboard spacer ring and discard it
     
    CV-joint boot
     
    Trilobal tri-pot bushing from the housing
     

  10.  
  11. Thoroughly clean and inspect all parts.
  12.  

To install:

  1. Install or connect the following:

    New snapring onto the stub shaft
     
    Small boot clamp
     
    CV-joint boot
     

  2.  
  3. 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).
  4.  
  5. Install or connect the following:
    NOTE
    Make sure the boot lies flat against the trilobal bushing.



    Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059, past the 2nd groove
     
    Tri-pot joint spider assembly onto the shaft until it passes the 2nd groove
     
    Outboard retaining ring into the axle shaft groove using Snapring Pliers tool J-8059
     
    Tri-pot joint spider assembly, slide it against the outboard retaining ring
     
    Inboard spacer ring, seat it in the groove
     
    1 / 2 of the kit grease into the boot
     
    1 / 2 of the kit grease into the tri-pot housing
     
    Trilobal tip-pot bushing flush with the tri-pot housing face
     
    New large seal clamp onto the CV-joint boot
     
    Tri-pot housing, slide it over the tri-pot joint spider assembly
     
    CV-joint boot/clamp, slide it into place, over the trilobal tri-pot bushing with the seal lip in the groove
     

  6.  
  7. 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)
  8.  
  9. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  10.  
  11. Install the halfshaft and the front wheel.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft and place it in a vise
     
    Snapring from the stub shaft and discard it
     
    Small CV-joint boot clamp, cut and discard it
     
    Large CV-joint boot clamp, cut and discard it
     
    CV-joint boot by sliding it away from the tri-pot joint
     

  4.  
  5. Install a Stub Shaft Removal tool J-38868-A to the stub shaft snapring groove.
  6.  
  7. Using a slide hammer puller, press the stub shaft from the tri-pot housing.
  8.  
  9. Remove or disconnect the following:

    Tri-pot housing from the tri-pot spider
     
    Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059
     
    Outboard retaining ring using Snapring Pliers tool J-8059 and discard it
     
    Tri-pot joint spider assembly
     
    Inboard spacer ring and discard it
     
    CV-joint boot
     
    Trilobal tri-pot bushing from the housing
     

  10.  
  11. Thoroughly clean and inspect all parts.
  12.  

To install:

  1. Install or connect the following:

    New snapring onto the stub shaft
     
    Small boot clamp
     
    CV-joint boot
     

  2.  
  3. 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).
    NOTE
    Make sure the boot lies flat against the trilobal bushing.



    Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059, past the 2nd groove
     
    Tri-pot joint spider assembly onto the shaft until it passes the 2nd groove
     
    Outboard retaining ring into the axle shaft groove using Snapring Pliers tool J-8059
     
    Tri-pot joint spider assembly, slide it against the outboard retaining ring
     
    Inboard spacer ring, seat it in the groove
     
    1 / 2 of the kit grease into the boot
     
    1 / 2 of the kit grease into the tri-pot housing
     
    Trilobal tip-pot bushing flush with the tri-pot housing face
     
    New large seal clamp onto the CV-joint boot
     
    Tri-pot housing, slide it over the tri-pot joint spider assembly
     
    CV-joint boot/clamp, slide it into place, over the trilobal tri-pot bushing with the seal lip in the groove
     

  4.  
  5. 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)
  6.  
  7. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  8.  
  9. Install the halfshaft and the front wheel.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft and place it in a vise
     
    Snapring from the stub shaft and discard it
     
    Small CV-joint boot clamp, cut and discard it
     
    Large CV-joint boot clamp, cut and discard it
     
    CV-joint boot by sliding it away from the tri-pot joint
     

  4.  
  5. Install a Stub Shaft Removal tool J-38868-A to the stub shaft snapring groove.
  6.  
  7. Using a slide hammer puller, press the stub shaft from the tri-pot housing.
  8.  
  9. Remove or disconnect the following:

    Tri-pot housing from the tri-pot spider
     
    Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059
     
    Outboard retaining ring using Snapring Pliers tool J-8059 and discard it
     
    Tri-pot joint spider assembly
     
    Inboard spacer ring and discard it
     
    CV-joint boot
     
    Trilobal tri-pot bushing from the housing
     

  10.  
  11. Throughly clean and inspect all parts.
  12.  

To install:

  1. Install or connect the following:

    New snapring onto the stub shaft
     
    Small boot clamp
     
    CV-joint boot
     

  2.  
  3. 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).
  4.  
  5. Install or connect the following:
    NOTE
    Make sure the boot lies flat against the trilobal bushing.



    Inboard spacer ring slide it rearward on the shaft using Snapring Pliers tool J-8059, past the 2nd groove
     
    Tri-pot joint spider assembly onto the shaft until it passes the 2nd groove
     
    Outboard retaining ring into the axle shaft groove using Snapring Pliers tool J-8059
     
    Tri-pot joint spider assembly, slide it against the outboard retaining ring
     
    Inboard spacer ring, seat it in the groove
     
    1 / 2 of the kit grease into the boot
     
    1 / 2 of the kit grease into the tri-pot housing
     
    Trilobal tip-pot bushing flush with the tri-pot housing face
     
    New large seal clamp onto the CV-joint boot
     
    Tri-pot housing, slide it over the tri-pot joint spider assembly
     
    CV-joint boot/clamp, slide it into place, over the trilobal tri-pot bushing with the seal lip in the groove
     

  6.  
  7. 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)
  8.  
  9. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  10.  
  11. Install the halfshaft and the front wheel.
  12.  

Outer CV-Joint
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft and position it in a vise
     
    Large CV-joint boot clamp and discard it
     
    Small CV-joint boot clamp and discard it
     
    CV-joint boot and slide it back on the shaft
     
    Outer race from the halfshaft by spreading the outer race-to-halfshaft retaining ring using Snapring Pliers J-8059
     
    Retaining ring from the halfshaft and discard it
     
    CV-joint boot from the halfshaft and discard it if damaged
     

  4.  
  5. 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.  

  6.  
  7. 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.  

  8.  
  9. Thoroughly clean and inspect all parts.
  10.  

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 of the kit grease into the CV-joint.
  8.  
  9. Install or connect the following:

    Small ring clamp on the CV boot
     
    New retaining ring on the halfshaft
     
    Large ring clamp on the CV boot
     
    Outer race assembly onto the halfshaft until the ring engages the halfshaft groove
     

  10.  
  11. 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.

  12.  
  13. 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).
  14.  
  15. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.
  16.  
  17. Install 1 / 2 of the kit grease into the CV-joint boot.
  18.  
  19. 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.

  20.  
  21. 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).
  22.  
  23. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  24.  
  25. Install the halfshaft and the front wheel.

    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint assemble

  26.  

  1. Place protective covers over the vise jaws. Place the halfshaft in the vise.
  2.  
  3. Use a hand grinder to cut through the swage ring. Use side cutters to cut off the small boot clamp.
  4.  
  5. Slide the boot down the halfshaft bar and away from the CV-joint outer race. Wipe all grease away from the face of the CV joint.
  6.  
  7. Find the halfshaft bar retaining snap ring, which is located in the inner race.
  8.  
  9. Spread the snapring ears apart.
  10.  
  11. Pull the CV joint and the CV joint boot from the halfshaft bar. Discard the old CV joint boot.
  12.  
  13. Place a brass drift against the CV joint cage. Tap gently on the brass drift with a hammer in order to tilt the cage.
  14.  
  15. Remove the first chrome alloy ball when the CV joint cage tilts. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball. Repeat this process to remove all six of the balls.
  16.  
  17. Pivot the CV joint cage and the inner race 90 degrees to the center line of the outer race. At the same time, align the cage windows with the lands of the outer race. Lift out the cage and the inner race.
  18.  
  19. Remove the inner race from the cage by rotating the inner race upward. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
    1. Inner and outer race assemblies.
    2.  
    3. CV joint cage.
    4.  
    5. Chrome alloy balls.
    6.  

  20.  
  21. Dry all the parts. Check the CV joint assembly for unusual wear, cracks, or other damage. Replace any damaged parts. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves).

    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint assembly

  22.  

To assemble:

  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.
  2.  
  3. 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.
  4.  
  5. Insert the cage and inner race into the outer race.
  6.  
  7. 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.
  8.  
  9. 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.
  10.  
  11. Place the new small boot clamp onto the CV joint boot.
  12.  
  13. Slide the CV joint boot onto the halfshaft bar.
  14.  
  15. Position the small end of the CV joint boot into the joint boot groove on the halfshaft bar.
  16.  
  17. Secure the small boot clamp, a breaker bar, and a torque wrench. Tighten the small clamp (1) to 100 ft. lbs. (136 Nm).
  18.  
  19. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
  20.  
  21. 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.
    NOTE
    Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation.

  22.  
  23. Slide the CV joint onto the halfshaft bar. The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint is in the proper position.
  24.  
  25. Pull on the CV joint to verify engagement.
  26.  
  27. 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.
  28.  
  29. Clamp the CV joint boot tightly to the CV joint outer race with the large swage ring, using the following procedure:
    1. Mount tool J36652 in a vise.
    2.  
    3. Install the bottom half of the split-plate swage clamp. For K15 models, use tool J36652-98.
    4.  
    5. For K25 models, use tool J36652-1.
    6.  
    7. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of tool J36652.
    8.  

  30.  
  31. Align the following during this procedure:
    1. CV joint boot.
    2.  
    3. CV joint assembly.
    4.  
    5. Swage ring.
    6.  

  32.  
  33. Install the top half of tool J36652 onto the lower half of the tool, over the CV joint boot and the CV joint assembly.
  34.  
  35. Align the swage ring and the swage ring clamp.
  36.  
  37. Insert the bolts into J36652. 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 the tool touch the bottom half of the tool.
  38.  
  39. Loosen the bolts and remove the halfshaft assembly from the tool.
  40.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft and position it in a vise
     
    Large CV-joint boot clamp and discard it
     
    Small CV-joint boot clamp and discard it
     
    CV-joint boot and slide it back on the shaft
     
    Outer race from the halfshaft by spreading the outer race-to-halfshaft retaining ring using Snapring Pliers J-8059
     
    Retaining ring from the halfshaft and discard it
     
    CV-joint boot from the halfshaft and discard it if damaged
     

  4.  
  5. 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.  

  6.  
  7. 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.  

  8.  
  9. Thoroughly clean and inspect all parts.
  10.  

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 of the kit grease into the CV-joint.
  8.  
  9. Install or connect the following:

    Small ring clamp on the CV boot
     
    New retaining ring on the halfshaft
     
    Large ring clamp on the CV boot
     
    Outer race assembly onto the halfshaft until the ring engages the halfshaft groove
     

  10.  
  11. 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.

  12.  
  13. 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).
  14.  
  15. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.
  16.  
  17. Install 1 / 2 of the kit grease into the CV-joint boot.
  18.  
  19. 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.

  20.  
  21. 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).
  22.  
  23. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  24.  
  25. Install the halfshaft and the front wheel.

    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint assembly-1999 models

  26.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft and position it in a vise
     
    Large CV-joint boot clamp and discard it
     
    Small CV-joint boot clamp and discard it
     
    CV-joint boot and slide it back on the shaft
     
    Outer race from the halfshaft by spreading the outer race-to-halfshaft retaining ring using Snapring Pliers J-8059
     
    Retaining ring from the halfshaft and discard it
     
    CV-joint boot from the halfshaft and discard it if damaged
     

  4.  
  5. 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.  

  6.  
  7. 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.  

  8.  
  9. Throughly clean and inspect all parts.
  10.  

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 of the kit grease into the CV-joint.
  8.  
  9. Install or connect the following:

    Small ring clamp on the CV boot
     
    New retaining ring on the halfshaft
     
    Large ring clamp on the CV boot
     
    Outer race assembly onto the halfshaft until the ring engages the halfshaft groove
     

  10.  
  11. 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.

  12.  
  13. 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).
  14.  
  15. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.
  16.  
  17. Install 1 / 2 of the kit grease into the CV-joint boot.
  18.  
  19. 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.

  20.  
  21. 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).
  22.  
  23. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  24.  
  25. Install the halfshaft and the front wheel.

    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint assemble

  26.  

 
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