SRX 2004-2005

CV-Joints

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Overhaul



Front & Rear Outer Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft.
  4.  
  5. Wrap a towel around the halfshaft and place it horizontally in a vise.
  6.  
  7. Remove the small and large seal clamps using side cutters.
  8.  
  9. Separate the seal from the joint outer race at the large end.
  10.  
  11. Wipe the grease away from the joint face.
  12.  
  13. Hold the outer joint housing horizontally and position a wood block between the seal and the joint on the joint face.
  14.  
  15. Hammer around the wood block to remove the outer joint from the axle shaft.
  16.  
  17. Remove and discard the shaft retaining ring.
  18.  
  19. Remove the seal from the shaft.
  20.  
  21. Remove the axle shaft from the vise.
  22.  
  23. Wrap a towel around the joint outer face and place the joint in a vise vertically.
  24.  
  25. Using a drift and hammer, tap gently on the inner cage until it tilts up enough to remove the first ball.
  26.  
  27. Repeat this procedure using the proper sequence until all the balls are removed.

    Click image to see an enlarged view

    Fig. CV joint ball removal and installation sequence

  28.  
  29. Position the cage and inner race 90° to the centerline of the outer race.
  30.  
  31. Remove the cage and inner race from the outer race.
  32.  
  33. Position the cage and inner race so the larger radius corners of the race windows are up. Rotate the inner race 90° to the centerline of the cage.
  34.  
  35. Align the lands of the inner race with the windows of the cage.
  36.  
  37. Insert an inner race land into a cage window.
  38.  
  39. Pivot the inner down and remove it from the cage.
  40.  
  41. Clean all parts thoroughly with solvent and allow to air dry.
  42.  
  43. Inspect all parts for wear or damage and replace as necessary.
  44.  

To assemble:

  1. Position the cage so the large radius corners of the cage windows are up.
  2.  
  3. Position the inner race 90° to the centerline of the cage.
  4.  
  5. Insert the inner race up through the bottom of the cage.
  6.  
  7. Align a land of the inner race to a window of the cage.
  8.  
  9. Insert the inner race land into the cage window.
  10.  
  11. Rotate the remainder of the inner race into the cage.
  12.  
  13. Align the inner race ball tracks with the cage windows.
  14.  
  15. Wrap a towel around the splined shaft and place the shaft vertically in a vise with the joint opening up.
  16.  
  17. Position the cage and inner race 90° to the centerline of the outer race.
  18.  
  19. Align 2 cage windows 180° apart.
  20.  
  21. Place a cage window and inner race ball track in position to insert the ball.
  22.  
  23. Insert a ball through the cage window and into the ball track. Tap the ball with a plastic hammer until it is fully engaged.
  24.  
  25. Repeat the procedure using the same sequence as the removal.
  26.  
  27. Insert about 60 percent of the grease from the service kit into the outer joint.
  28.  
  29. Remove the outer joint from the vise.
  30.  
  31. Wrap a towel around the axle shaft and place it horizontally in a vise.
  32.  
  33. Install a new small seal retaining clamp on the axle shaft.
  34.  
  35. Install the seal on the axle shaft.
  36.  
  37. Install a new retaining ring on the axle shaft.
  38.  
  39. Position the outer joint horizontally.
  40.  
  41. Engage the inner race splines into the axle shaft splines.
  42.  
  43. Press the end of the retaining ring into the axle shaft groove while firmly pressing the outer joint onto the axle shaft. The axle shaft and inner race must be fully seated to each other.
  44.  
  45. Using a wood block, tap the outer joint on until it is fully seated on the axle shaft.
  46.  
  47. Install the remaining grease into the seal boot.
  48.  
  49. Position the small end of the inner joint seal into the inner joint seal groove.
  50.  
  51. Crimp the small seal clamp until the crimping joint gap is 0.039 inch (1mm).
  52.  
  53. Position the large clamp onto the boot seal
  54.  
  55. Slide the large inboard seal with the large clamp in place, over the bushing and locate the lip of the seal in the groove.
  56.  
  57. Ensure the seal is properly shaped around the circumference of the joint.
  58.  
  59. Remove the air from the inner joint seal.
  60.  
  61. Using crimping pliers, crimp the large clamp around the boot, until the crimping joint gap is 0.039 inch (1mm).
  62.  
  63. Rotate the outer joint a few times to fully distribute the gear into the bearings.
  64.  

Front Inner Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft.
  4.  
  5. Wrap a towel around the halfshaft and place it horizontally in a vise.
  6.  
  7. Remove the small seal clamp using side cutters.
  8.  
  9. Remove the large seal clamp from the tripot joint.
  10.  
  11. Separate the inboard joint seal from the tripot bushing.
  12.  
  13. Slide the seal away from the joint.
  14.  
  15. Remove the housing from the tripot joint spider and the shaft bar.
  16.  
  17. Remove the retaining ring.
  18.  
  19. Reference mark the position of the tripot spider on the shaft bar.
  20.  
  21. Using a drift and hammer, tap around the spider face to remove the joint from the bar.
  22.  
  23. Remove the joint seal from the bar.
  24.  
  25. Inspect the parts for wear or damage and replace as necessary.
  26.  

To assemble:

  1. Place a new small seal clamp on the small end of the inner joint seal.
  2.  
  3. Slide the inner joint seal and the small seal clamp into the boot groove on the shaft bar.
  4.  
  5. Position the small end of the inner joint seal into the inner joint seal groove.
  6.  
  7. Crimp the small seal clamp until the crimping joint gap is 0.039 inch (1mm).
    NOTE
    The clamping hold time must be no less than 2 seconds.

  8.  
  9. Align the reference marks and install the tripot spider to the shaft bar.
  10.  
  11. Install a new retaining ring.
  12.  
  13. Pull out on the spider to verify that the spider is fully engaged.
  14.  
  15. Place half of the grease from the service kit in the shaft inboard seal. Use the remainder of the grease to repack the housing.
  16.  
  17. Install the tripot bushing to the housing.
  18.  
  19. Position the large seal clamp on the inboard seal.
  20.  
  21. Slide the housing over the joint spider.
  22.  
  23. Slide the large inboard seal with the large clamp in place, over the bushing and locate the lip of the seal in the groove.
  24.  
  25. Ensure the seal is properly shaped around the circumference of the joint.
  26.  
  27. Measure the distance (a) between the seal edges. The correct distance is 4.12 inches (104.7mm).
  28.  
  29. Remove the air from the inner joint seal.
  30.  
  31. Using crimping pliers, crimp the large clamp around the boot, ensuring the tangs are fully engaged.
  32.  
  33. Rotate the inner tripot housing a few times to fully distribute the gear into the bearings.

    Click image to see an enlarged view

    Fig. Exploded view of front inner CV joint assembly



    Click image to see an enlarged view

    Fig. Measuring installed boot seal distance-front inner joint

  34.  

Rear Inner Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft:
  4.  
  5. Wrap a towel around the halfshaft and place it horizontally in a vise.
  6.  
  7. Remove the small and large seal clamps using side cutters.
  8.  
  9. Separate the seal from the joint outer race at the large end.
  10.  
  11. Slide the seal away from the joint face.
  12.  
  13. Wipe the grease away from the joint face.
  14.  
  15. Hold the inner joint housing horizontally and position a drift on the inner face.
  16.  
  17. Tap the drift to compress the axle shaft retaining ring.
  18.  
  19. Remove and discard the shaft retaining ring.
  20.  
  21. Use the hammer and drift again to remove the inner joint.
  22.  
  23. Remove the seal from the shaft.
  24.  
  25. Remove the axle shaft from the vise.
  26.  
  27. Wrap a towel around the joint outer face and place the joint in a vise vertically.
  28.  
  29. Using a drift and hammer, tap gently on the inner cage until it tilts up enough to remove the first ball.
  30.  
  31. Repeat this procedure using the proper sequence until all the balls are removed.
  32.  
  33. Position the cage and inner race 90°to the centerline of the outer race.
  34.  
  35. Remove the cage and inner race from the outer race.
  36.  
  37. Position the cage and inner race so the larger radius corners of the race windows are up. Rotate the inner race 90° to the centerline of the cage.
  38.  
  39. Align the lands of the inner race with the windows of the cage.
  40.  
  41. Insert an inner race land into a cage window.
  42.  
  43. Pivot the inner down and remove it from the cage.
  44.  
  45. Clean all parts thoroughly with solvent and allow to air dry.
  46.  
  47. Inspect all parts for wear or damage and replace as necessary.
  48.  

To assemble:

  1. Position the cage so the large radius corners of the cage windows are up.
  2.  
  3. Position the inner race 90° to the centerline of the cage.
  4.  
  5. Insert the inner race up through the bottom of the cage.
  6.  
  7. Align a land of the inner race to a window of the cage.
  8.  
  9. Insert the inner race land into the cage window.
  10.  
  11. Rotate the remainder of the inner race into the cage.
  12.  
  13. Align the inner race ball tracks with the cage windows.
  14.  
  15. Wrap a towel around the splined shaft and place the shaft vertically in a vise with the joint opening up.
  16.  
  17. Position the cage and inner race 90° to the centerline of the outer race.
  18.  
  19. Align 2 cage windows 180° apart.
  20.  
  21. Place a cage window and inner race ball track in position to insert the ball.
  22.  
  23. Insert a ball through the cage window and into the ball track. Tap the ball with a plastic hammer until it is fully engaged.
  24.  
  25. Repeat the procedure using the same sequence as in removal.
  26.  
  27. Insert about 60 percent of the grease from the service kit into the inner joint.
  28.  
  29. Remove the inner joint from the vise.
  30.  
  31. Wrap a towel around the axle shaft and place it horizontally in a vise.
  32.  
  33. Install a new small seal retaining clamp on the axle shaft.
  34.  
  35. Install the seal on the axle shaft.
  36.  
  37. Install a new retaining ring on the axle shaft.
  38.  
  39. Position the inner joint horizontally.
  40.  
  41. Engage the inner race splines into the axle shaft splines.
  42.  
  43. Press the end of the retaining ring into the axle shaft groove while firmly pressing the inner joint onto the axle shaft. The axle shaft and inner race must be fully seated to each other.
  44.  
  45. Using a wood block, tap the inner joint on until it is fully seated on the axle shaft.
  46.  
  47. Install the remaining grease into the seal boot.
  48.  
  49. Position the small end of the inner joint seal into the inner joint seal groove.
  50.  
  51. Crimp the small seal clamp until the crimping joint gap is 0.039 inch (1mm).
  52.  
  53. Position the large clamp onto the boot seal
  54.  
  55. Slide the large inboard seal with the large clamp in place, over the bushing and locate the lip of the seal in the groove.
  56.  
  57. Ensure the seal is properly shaped around the circumference of the joint.
  58.  
  59. Measure the distance (a) between the seal edges. The correct distance is 3.42 inches (86.85mm) for AWD, or 3.50 inches (88.6mm)
  60.  
  61. Using crimping pliers, crimp the large clamp around the boot, until the crimping joint gap is 0.039 inch (1mm).
  62.  
  63. Rotate the inner joint a few times to fully distribute the gear into the bearings.

    Click image to see an enlarged view

    Fig. Measuring installed boot seal distance-Rear inner joint

  64.  

 
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