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    2008 Toyota Truck FJ Cruiser 4WD 4.0L SFI DOHC 6cyl

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

    Halfshafts

    Print

    CV-Joints



    Overhaul
    Inner Joint

    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

    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 toward 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 1500 models, use tool J36652-98. For 2500 models, use tool J36652-1.
    24.  
    25. Check the inboard stroke position. Use measurement A for the 1500 models. Use measurement B for the 2500 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 1500 models, use tool J36652-98. For 2500 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.  


    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

    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 1500 models, use tool J36652-98. For 2500 models, use tool J36652-1.
    24.  
    25. Check the inboard stroke position. Use measurement A for the 1500 models. Use measurement B for the 2500 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 1500 models, use tool J36652-98. For 2500 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.  

    Outer Joint
    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 1500 models, use tool J36652-98.
      4.  
      5. For 2500 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. 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 1500 models, use tool J36652-98.
      4.  
      5. For 2500 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.  

    Removal & Installation



    1. Remove or disconnect the following:

      Wheels
       

    2.  
    3. Insert a drift or a large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the drive axle wheel drive shaft from turning.
    4.  
    5. Remove or disconnect the following:
      NOTE
      Do not reuse the hub nut. A new nut must be used when installing the wheel drive shaft.



      Nut and the washer from the hub
       



      Bolts (6) securing the wheel drive shaft inboard flange to the output shaft flange
       
      Drift from the rotor
       
      Stabilizer shaft link from the lower control arm
       

    6.  
    7. Wrap shop towels around both the inner and the outer wheel drive shaft boots in order to avoid damage to the boots during removal and installation.
    8.  
    9. Pull the wheel drive shaft through the lower control arm opening.
    10.  

    To install:

    Click image to see an enlarged view

    Fig. The halfshaft is mounted to the flange on the differential and through the hub assembly-4-wheel drive models

    1. Wrap shop towels around both the inner and the outer wheel drive shaft boots in order to avoid damage to the boots during removal and installation.
      NOTE
      Clean the steering knuckle and the wheel drive shaft splines and threads. These areas must be dry and free of grease, dirt, and contamination.

    2.  
    3. Insert the wheel drive shaft splined shank into the knuckle hub.
      NOTE
      Use only a genuine GM front wheel drive shaft nut. Installation of anything but an OEM front wheel drive shaft nut could cause damage to the vehicle.

    4.  
    5. Install or connect the following:

      Washer and the new hub nut to the wheel driveshaft. Do not tighten.
       
      The wheel drive shaft inboard flange to the output shaft flange using the inboard flange bolts
       

    6.  
    7. Insert a drift or a large screwdriver through the brake caliper into 1 of the brake rotor vanes in order to prevent the wheel drive shaft from turning. Tighten the inboard flange bolts to 58 ft. lbs. (78 Nm). Tighten the hub nut to 177 ft. lbs. (240 Nm).
    8.  
    9. Remove the drift from the rotor.
    10.  
    11. Install the stabilizer shaft link.
    12.  
    13. Install the wheel and tire assembly.
    14.  

    1. Remove or disconnect the following:

      Wheels
       

    2.  
    3. Insert a drift or a large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the drive axle wheel drive shaft from turning.
    4.  
    5. Remove or disconnect the following:
      NOTE
      Do not reuse the hub nut. A new nut must be used when installing the wheel drive shaft.



      Nut and the washer from the hub
       



      Bolts (6) securing the wheel drive shaft inboard flange to the output shaft flange
       
      Drift from the rotor
       
      Stabilizer shaft link from the lower control arm
       

    6.  
    7. Wrap shop towels around both the inner and the outer wheel drive shaft boots in order to avoid damage to the boots during removal and installation.
    8.  
    9. Pull the wheel drive shaft through the lower control arm opening.
    10.  

    To install:

    Click image to see an enlarged view

    Fig. The halfshaft is mounted to the flange on the differential and through the hub assembly-4-wheel drive models

    1. Wrap shop towels around both the inner and the outer wheel drive shaft boots in order to avoid damage to the boots during removal and installation.
      NOTE
      Clean the steering knuckle and the wheel drive shaft splines and threads. These areas must be dry and free of grease, dirt, and contamination.

    2.  
    3. Insert the wheel drive shaft splined shank into the knuckle hub.
      NOTE
      Use only a genuine GM front wheel drive shaft nut. Installation of anything but an OEM front wheel drive shaft nut could cause damage to the vehicle.

    4.  
    5. Install or connect the following:

      Washer and the new hub nut to the wheel driveshaft. Do not tighten.
       
      The wheel drive shaft inboard flange to the output shaft flange using the inboard flange bolts
       

    6.  
    7. Insert a drift or a large screwdriver through the brake caliper into 1 of the brake rotor vanes in order to prevent the wheel drive shaft from turning. Tighten the inboard flange bolts to 58 ft. lbs. (78 Nm). Tighten the hub nut to 177 ft. lbs. (240 Nm).
    8.  
    9. Remove the drift from the rotor.
    10.  
    11. Install the stabilizer shaft link.
    12.  
    13. Install the wheel and tire assembly.
    14.  

     
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