Neon, 2000 - 2005

Tri-Pod (Inner) Joint

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  1. Remove or disassemble the following:
    WARNING
    When removing the spider joint, hold the rollers in place on the trunnions to keep the rollers and needle bearings in place.


    NOTE
    If necessary, tap the spider assembly from the shaft with a brass drift.


    WARNING
    When removing the spider assembly, do not hit the outer bearings.


    WARNING
    If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable.



    Halfshaft and place it in a soft-jawed vise
     
    Tri-pod joint boot clamps and the boot down the shaft
     



    Spider/shaft assembly from the tri-pod housing
     
    Snap ring from the shaft
     
    Spider assembly
     



    Boot by sliding it off the shaft
     



    Click image to see an enlarged view

    Fig. View of the halfshaft assemblies-Typical



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    Fig. Exploded view of the halfshaft assembly-Typical



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    Fig. Positioning the boot on the shaft-Tri-pod and Rzeppa joints



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    Fig. Adjusting the Tri-pod boot length-Hytrel plastic boot



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    Fig. Adjusting the Tri-pod boot length-Silicone rubber boot



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    Fig. Tightening the high profile boot clamp-Tri-pod joint (Hytrel plastic) boot and Rzeppa joint boots



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    Fig. Tightening the low profile boot clamp-Silicone rubber Tri-pod boot



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    Fig. Secured the low profile boot clamp-Silicone rubber Tri-pod boot

  2.  

To assemble:


WARNING
The Tri-pod sealing boots are made of 2 different types of material; silicon rubber (high temperature) which is soft and pliable or Hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot made of the correct material.

  1. Install a new small boot clamp and slide it on the shaft.
  2.  
  3. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove.
  4.  
  5. If installing a new boot, distribute 1 / 2 of the grease in the service package inside the tri-pod housing and the other 1 / 2 inside the boot.
  6.  
  7. Install or connect the following:
    WARNING
    If necessary, tap the spider assembly onto the shaft using a brass drift; be careful not to hit the outer bearings.



    Spider assembly, face the chamfered side toward the shaft
     



    Snap ring making sure it is fully seated in the groove
     
    Spider/shaft assembly into the tri-pod housing
     
    New inner boot clamp and position it evenly on the sealing boot
     

  8.  
  9. Using a trim stick, adjust the boot length to 107mm (Hytrel plastic) or 115mm (silicone rubber).
  10.  
  11. If installing a high profile boot clamp, perform the following procedure:
    1. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
      WARNING
      The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand.

    2.  
    3. Position the boot onto the tri-pod housing retaining groove and install the retaining clamp evenly on the boot.
    4.  
    5. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
    6.  

  12.  
  13. If installing a low profile latching type boot clamp, position Snap-On® Clamp Locking Tool YA3050 prongs in the clamp holes and squeeze the tool until the upper clamp band is latched behind the 2 tabs on the lower clamp band.
  14.  
  15. Install the halfshaft.
  16.  

 
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