REMOVAL & INSTALLATION
See Figure 1
- Disconnect the negative battery cable.
- Raise and support the vehicle safely.
The driveshaft is a balanced unit. Before removing the drive shaft, matchmark the driveshaft in relationship to the flange on the transfer case and the flange on the rear axle so that it may be installed in its original position.
- Remove the bolts retaining the driveshaft to the transfer case.
- Remove the bolts retaining the driveshaft to the rear axle flange.
- Remove the driveshaft.
- Position the driveshaft to the rear axle flange so that the marks made previously are line up. Install and tighten the retaining bolts to 61-87 ft. lbs. (83-118Nm).
- Position the driveshaft to the transfer case flange so that the marks made previously are line up. Install and tighten the retaining bolts to 61-87 ft. lbs. (83-118Nm).
- Lower the vehicle.
- Reconnect the negative battery cable.
DISASSEMBLY & ASSEMBLY
See Figures 2, 3, 4 and 5
- Place the driveshaft on a suitable workbench.
The CV joint components are matched. Extreme care should be take not to mix or substitute components.
- Remove the clamp retaining the shroud to the outer bearing race and flange assembly.
- Carefully tap the shroud lightly with a blunt tool and remove the shroud. Be careful not to damage the shroud, dust boot or outer bearing race and flange assembly.
- Peel the boot upward and away from the outer bearing race and flange assembly.
- Remove the wire ring that retains the inner race to the outer race.
- Remove the inner race and shaft assembly from the outer race and flange assembly. Remove the cap and spring from inside the outer retainer.
- Remove the circlip retaining the inner race assembly to the shaft, using snapring pliers. Discard the clip and remove the inner race assembly.
- If required, remove the clamp retaining the boot to the shaft and remove the boot.
- Carefully pry the ball bearings from the cage. Be careful not to scratch or damage the cage, race or ball bearings.
- Rotate the inner race to align with the cage windows and remove the inner race through the wider end of the cage.
- Install the inner bearing race in the bearing cage. Install the race through the large end of the cage with the counterbore facing the large end of the cage.
- Push the race to the top of the cage and rotate the race until all the ball slots are aligned with the windows. This will lock the race to the top of the cage.
- With the bearing cage and inner race properly aligned, install the ball bearings. The bearings can be pressed through the bearing cage with the heel of the hand. Repeat this step until the remaining ball bearings are installed.
- If removed, install a new dust boot on the shaft, using a new clamp. Make certain the boot is seated in its groove.
The clamp is a fixed diameter push-on metal ring.
- Install the inner bearing assembly on the shaft. Make certain the circlip is exposed.
- Install a new circlip on the shaft. Do not over-expand or twist the circlip during installation.
- Install the spring and cap in the outer bearing retainer and flange.
- Fill the outer bearing retainer with 3 oz. of Constant Velocity Joint Grease, D8RZ-19590-A or equivalent.
- Insert the inner race and shaft assembly in the outer bearing retainer and flange.
- Push the inner race down until the wire spring groove is visible and install the wire ring.
- Fill the top of the outer bearing retainer with Constant Velocity Joint Grease, D8RZ-19590-A or equivalent. Remove all excess grease from the external surfaces.
- Pull the dust boot over the retainer. Make certain the boot is seated in the groove and that any air pressure which may have built up in the boot is relieved.
Insert a dulled screwdriver blade between the boot and outer bearing retainer and allow the trapped air to escape from the boot.
- Install the shroud over the boot and retainer and install the clamp.