Isuzu Ascender 2003-05

CV-Joint Boots

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Replacement



Outer Boot
  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. Install12
  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
  12.  


NOTE
Make sure the boot lies flat against the halfshaft.

  1. 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).
  2.  
  3. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.
  4.  
  5. Install12
  6.  
  7. Measure approximately 0.687 in. (17.5mm) up from the bottom edge of the outer CV-joint assembly.
  8.  
  9. Slide the large end of the CV boot/clamp into place, with the seal lip in place over the outer race.
  10.  


NOTE
Make sure the boot lies flat against the outer race.

  1. 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).
  2.  
  3. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  4.  
  5. Install the halfshaft and the front wheel.
  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint Assembly


 
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