DIFFERENTIAL AND DRIVELINE - ertyu.org · differential and driveline table of contents page page description and operation front driveshafts .....1 diagnosis and testing driveshaft

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DIFFERENTIAL AND DRIVELINE

TABLE OF CONTENTS

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ESCRIPTION AND OPERATIONFRONT DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . 1IAGNOSIS AND TESTINGDRIVESHAFT DIAGNOSIS. . . . . . . . . . . . . . . . . . . 2EMOVAL AND INSTALLATIONDRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ISASSEMBLY AND ASSEMBLYDRIVESHAFT RECONDITION . . . . . . . . . . . . . . . . 7

INNER TRIPOD JOINT SEAL BOOT . . . . . . . . . . . 7OUTER C/V JOINT SEAL BOOT . . . . . . . . . . . . . 13

SPECIFICATIONSTORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SPECIAL TOOLSDRIVESHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

ESCRIPTION AND OPERATION

RONT DRIVESHAFTSVehicles equipped with either an automatic oranual transmission use an unequal–length drive-

haft system.

Fig. 1 Unequal Leng1 – STUB AXLE2 – OUTER C/V JOINT3 – OUTER C/V JOINT BOOT4 – TUNED RUBBER DAMPER WEIGHT5 – INTERCONNECTING SHAFT6 – OUTER C/V JOINT BOOT7 – STUB AXLE

The system incorporates two driveshaft assemblies(left and right) that consist of an inner and outerconstant velocity (CV) joint and a solid interconnect-ing shaft (Fig. 1). The right driveshaft is longer thanthe left due to transaxle packaging and powertraindesign.

riveshaft System8 – OUTER C/V JOINT9 – RIGHT DRIVESHAFT10 – INNER TRIPOD JOINT BOOT11 – INNER TRIPOD JOINT12 – INNER TRIPOD JOINT13 – INNER TRIPOD JOINT BOOT14 – INTERCONNECTING SHAFT LEFT DRIVESHAFT

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DESCRIPTION AND OPERATION (Continued)

Driveshafts used on both the right and left sides ofhe vehicle use a tuned rubber damper weightounted to the interconnecting shaft (Fig. 1). The

amper weight applications vary by which side of theehicle the driveshaft is located on and the transmis-ion application of the vehicle. When replacing ariveshaft, be sure the replacement driveshaft hashe same damper weight as the original.

Both driveshaft assemblies use the same type ofnner and outer joints. The inner joint of both drive-haft assemblies is a tripod joint, and the outer jointf both driveshaft assemblies is a Rzeppa joint. Bothripod joints and Rzeppa joints are true constantelocity (C/V) joint assemblies. The inner tripod jointllows for the changes in driveshaft length throughhe jounce and rebound travel of the front suspen-ion.On vehicles equipped with ABS brakes, the outer/V joint is equipped with a tone wheel used toetermine vehicle speed for ABS brake operation.The inner tripod joint of both driveshafts is splined

nto the transaxle side gears. The inner tripod jointsre retained in the side gears of the transaxle usingsnap ring located in the stub shaft of the tripod

oint. The outer C/V joint has a stub shaft that isplined into the wheel hub and retained by a singleiece steel hub nut (Fig. 2). The hub nut is a lockingtyle; the nut lock, anti-rattle washer, and cotter pinre not necessary.

Fig. 2 Driveshaft Retaining Nut1 – DRIVESHAFT2 – HUB3 – HUB NUT

NOTE: This vehicle does not use a rubber–lip bear-ing seal as on previous front–wheel–drive cars toprevent contamination of the front wheel bearing.On these vehicles, the face of the outer C/V jointfits deeply into the steering knuckle, using a closeouter C/V joint–to–steering knuckle fit. This designdeters direct water splash on bearing seal whileallowing any water that gets in, to run out the bot-tom of the steering knuckle bearing bore. It isimportant to thoroughly clean the outer C/V jointand the wheel bearing area in the steering knucklebefore it is assembled after servicing.

DIAGNOSIS AND TESTING

DRIVESHAFT DIAGNOSIS

VEHICLE INSPECTION(1) Check for grease in the vicinity of the inboard

tripod joint and outboard C/V joint; this is a sign ofinner or outer joint seal boot or seal boot clamp dam-age.

(2) A light film of grease may appear on the rightinner tripod joint seal boot; this is considered normaland should not require replacement of the seal boot.The right inner tripod joint seal boot is made of sili-cone rubber; which will allow the weeping (sweating)of the joint lubricant to pass through it while in oper-ation.

NOISE AND/OR VIBRATION IN TURNSA clicking noise and/or a vibration in turns could

be caused by one of the following conditions.(1) Damaged outer C/V or inner tripod joint seal

boot or seal boot clamps. This will result in the lossand/or contamination of the joint grease, resulting ininadequate lubrication of the joint.

(2) Noise may also be caused by another compo-nent of the vehicle coming in contact with the drive-shafts.

CLUNKING NOISE DURING ACCELERATIONThis noise may be a result of one of the following

conditions:(1) A torn seal boot on the inner or outer joint of

the driveshaft assembly.(2) A loose or missing clamp on the inner or outer

joint of the driveshaft assembly.(3) A damaged or worn driveshaft C/V joint.

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DIAGNOSIS AND TESTING (Continued)

HUDDER OR VIBRATION DURING ACCELERATION(1) A worn or damaged driveshaft inner tripod

oint.(2) A sticking tripod joint spider assembly (inner

ripod joint only).(3) Improper wheel alignment. See Wheel Align-ent in this group for alignment checking and set-

ing procedures and specifications.

IBRATION AT HIGHWAY SPEEDS(1) Foreign material (mud, etc.) packed on the

ackside of the wheel(s).(2) Out of balance front tires or wheels. See Group

2, Wheels And Tires for the required balancing pro-edure.(3) Improper tire and/or wheel runout. See Group

2, Wheels And Tires for the required runout check-ng procedure.

EMOVAL AND INSTALLATION

RIVESHAFTS

AUTION: Boot sealing is vital to retain specialubricants and to prevent foreign contaminantsrom entering the C/V joint. Mishandling, such asllowing the assemblies to dangle unsupported, orulling or pushing the ends can cut boots or dam-ge C/V joints. During removal and installation pro-edures, always support both ends of the driveshafto prevent damage.

EMOVAL

AUTION: The driveshaft, when installed, acts as aolt and secures the front hub/bearing assembly. Ifehicle is to be supported or moved on its wheelsith a driveshaft removed, install a PROPER–SIZEDOLT AND NUT through front hub. Tighten bolt andut to 203 N·m (150 ft. lbs.). This will ensure that

he hub bearing cannot loosen.

(1) Disconnect battery negative cable.(2) Place transaxle in gated park.(3) Raise vehicle on hoist.(4) Remove wheel and tire assembly (Fig. 3).

(5) Remove the driveshaft to hub and bearingretaining nut (Fig. 4).

(6) If equipped with ABS, disconnect the frontwheel speed sensor and secure harness out of theway.

Fig. 3 Wheel and Tire Removal1 – WHEEL/TIRE ASSY.2 – LUG NUT (5)3 – HUB

Fig. 4 Driveshaft Retaining Nut Removal1 – DRIVESHAFT2 – HUB3 – HUB NUT

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REMOVAL AND INSTALLATION (Continued)

(7) Remove nut and bolt (Fig. 5) retaining balloint stud into steering knuckle.

OTE: Use caution when separating ball joint studrom steering knuckle, so ball joint seal does notet damaged.

(8) Separate ball joint stud from steering knuckley prying down on lower control arm (Fig. 6).

Fig. 5 Steering Knuckle at Lower Control Arm BallJoint

1 – NUT2 – BOLT3 – BALL JOINT

Fig. 6 Separating Lower Control Arm from SteeringKnuckle

1 – STEERING KNUCKLE2 – PRY BAR3 – LOWER CONTROL ARM4 – BALL JOINT STUD

NOTE: Care must be taken not to separate theinner C/V joint during this operation. Do not allowdriveshaft to hang by inner C/V joint, driveshaftmust be supported.

(9) Remove driveshaft from steering knuckle bypulling outward on knuckle while pressing in ondriveshaft. Support outer end of driveshaft assembly.If difficulty in separating driveshaft from steeringknuckle is encountered, perform the following proce-dure:

(a) Install Puller, Special Tool 6790 on hub andbearing assembly (Fig. 7), using wheel lug nuts tosecure it in place.

(b) Install a wheel lug nut on wheel stud to pro-tect the threads on the stud. Install a flat bladepry tool to keep hub from turning. Using Puller,force the driveshaft outer stub axle from the huband bearing assembly (Fig. 8).

(c) Pull steering knuckle assembly out and awayfrom outer C/V joint of the driveshaft assembly asshown in (Fig. 5).

(10) Support outer end of the driveshaft assembly.

NOTE: Removal of the inner tripod joints is madeeasier if you apply outward pressure on the joint asyou strike the punch with a hammer.

Fig. 7 Puller Installed On Hub/Bearing Assembly1 – TOOL 6790

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(11) Remove the inner tripod joints from the sideears of the transaxle using a punch to dislodge thenner tripod joint retaining ring from the transaxleide gear. If removing the right side inner tripodoint, position the punch against the inner tripodoint (Fig. 9). Strike the punch sharply with a ham-

er to dislodge the right inner joint from the sideear. If removing the left side inner tripod joint, posi-ion the punch in the groove of the inner tripod jointFig. 10). Strike the punch sharply with a hammer toislodge the left inner tripod joint from the side gear.

Fig. 8 Removing Stub Axle From Hub/Bearing1 – TOOL 6790

Fig. 9 Disengaging Right Inner Tripod Joint fromTransaxle

1 – TRANSAXLE2 – RIGHT INNER TRIPOD JOINT3 – PUNCH

(12) Hold inner tripod joint and interconnectingshaft of driveshaft assembly (Fig. 11). Remove innertripod joint from transaxle by pulling it straight outof transaxle side gear and transaxle oil seal. Whenremoving tripod joint, do not let spline or snapring drag across sealing lip of the transaxle totripod joint oil seal. When tripod joint isremoved from transaxle, some fluid will leakout.

Fig. 10 Disengaging Left Inner Tripod Joint fromTransaxle

1 – FRONT SUSPENSION CROSSMEMBER2 – DRIFT3 – TRANSAXLE4 – DRIVESHAFT INNER TRIPOD JOINT5 – NOTCH

Fig. 11 Tripod Joint Removal from Transaxle1 – INNER TRIPOD JOINT2 – TRANSAXLE3 – SPLINE4 – OIL SEAL5 – SNAP RING6 – INTERCONNECTING SHAFT

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AUTION: The driveshaft, when installed, acts as aolt and secures the front hub/bearing assembly. Ifehicle is to be supported or moved on its wheelsith a driveshaft removed, install a PROPER–SIZEDOLT AND NUT through front hub. Tighten bolt andut to 203 N·m (150 ft. lbs.). This will ensure that

he hub bearing cannot loosen.

NSTALLATION(1) Thoroughly clean spline and oil seal sealing

urface, on tripod joint. Lightly lubricate oil sealealing surface on tripod joint with fresh clean trans-ission lubricant.(2) Holding driveshaft assembly by tripod joint and

nterconnecting shaft, install tripod joint into tran-axle side gear as far as possible by hand.(3) Carefully align tripod joint with transaxle side

ears. Then grasp driveshaft interconnecting shaftnd push tripod joint into transaxle side gear untilully seated. Test that snap ring is fully engagedith side gear by attempting to remove tripod

oint from transaxle by hand. If snap ring isully engaged with side gear, tripod joint willot be removable by hand.(4) Clean all debris and moisture out of steering

nuckle (Fig. 12).

(5) Ensure that front of outer C/V joint, which fitsnto steering knuckle (Fig. 13), is free of debris and

oisture before assembling into steering knuckle.

Fig. 12 Steering Knuckle to C/V Joint Sealing Area1 – STEERING KNUCKLE2 – WHEEL BEARING3 – FRONT HUB4 – THIS AREA OF THE STEERING KNUCKLE IS TO BE FREE

OF ALL DEBRIS AND MOISTURE BEFORE INSTALLINGDRIVE SHAFT IN STEERING KNUCKLE

(6) Slide driveshaft back into front hub. Installsteering knuckle onto the ball joint stud (Fig. 14).

NOTE: At this point, the outer joint will not seatcompletely into the front hub. The outer joint will bepulled into hub and seated when the hub nut isinstalled and torqued.

(7) Install a NEW steering knuckle to ball jointstud bolt and nut (Fig. 14). Tighten the nut and boltto 95 N·m (70 ft. lbs.).

Fig. 13 Outer C/V Joint Inspection1 – OUTER C/V JOINT2 – THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL

DEBRIS AND MOISTURE, BEFORE INSTALLATION INTOSTEERING KNUCKLE.

Fig. 14 Driveshaft Installation Into Hub And SteeringKnuckle

1 – NUT2 – BOLT3 – BALL JOINT

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(8) Clean all foreign matter from threads of drive-haft outer stub axle. Install hub nut onto thehreads of the stub axle and tighten nut to 244 N·m180 ft. lbs.) (Fig. 15).

(9) Install front wheel and tire assembly. Installront wheel lug nuts (Fig. 16) and tighten to 128 N·m95 ft. lbs.).

Fig. 15 Driveshaft Retaining Nut Installation1 – DRIVESHAFT2 – HUB3 – HUB NUT

Fig. 16 Wheel and Tire Installation1 – WHEEL/TIRE ASSY.2 – LUG NUT (5)3 – HUB

(10) Check for correct fluid level in transaxleassembly. Refer to Group 21 Transaxle, for the cor-rect fluid level checking procedure for the type oftransaxle being checked.

(11) Lower vehicle.(12) Connect battery negative cable.

DISASSEMBLY AND ASSEMBLY

DRIVESHAFT RECONDITION

NOTE: The only service that is to be performed onthe driveshaft assemblies is the replacement of thedriveshaft seal boots.

If any failure of internal driveshaft components isdiagnosed during a vehicle road test or disassemblyof the driveshaft, the driveshaft will need to bereplaced as an assembly.

NOTE: Lubricant requirements and quantities aredifferent for inner joints than for outer joints. Useonly the recommended lubricants in the requiredquantities when servicing driveshaft assemblies.

See (Fig. 17) for the exploded view of the frontdriveshaft components.

INNER TRIPOD JOINT SEAL BOOT

REMOVALTo remove sealing boot from driveshaft for replace-

ment, the driveshaft assembly must be removed fromthe vehicle. See Driveshaft Removal and Installationin this section for the required driveshaft removaland replacement procedure.

The inner tripod joints use no internal retention inthe tripod housing to keep the spider assembly in thehousing. Therefore, do not pull on the interconnect-ing shaft to disengage tripod housing from transmis-sion stub shaft. Removal in this manner will causedamage to the inboard joint sealing boots.

(1) Remove the driveshaft requiring boot replace-ment from the vehicle. See Driveshaft Removal andInstallation in this section for the required driveshaftremoval procedure.

(2) Remove large boot clamp that retains inner tri-pod joint sealing boot to tripod joint housing (Fig. 18)and discard. Then remove small clamp that retainsinner tripod joint sealing boot to interconnectingshaft and discard. Remove the sealing boot from thetripod housing and slide it down the interconnectingshaft.


DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 17 Driveshaft Assembly Components (Exploded View)

1 – HOUSING ASM, RETAINER &2 – RING, SPACER3 – SPIDER, TRIPOTD JOINT4 – RING, RETAINING5 – RETAINER, BALL & ROLLER6 – BALL, TRIPOD JOINT7 – ROLLER, NEEDLE8 – CLAMP, SEAL RETAINING9 – BUSHING, TRILOBAL TRIPOD10 – SEAL, DRIVE AXLE INBOARD

11 – CLAMP, SEAL RETAINING12 – SHAFT, AXLE (RH SHOWN, LH SIMILAR)13 – SEAL, DRIVE AXLE OUTBOARD14 – CLAMP, SEAL RETAINING15 – RING, RACE RETAINING16 – BALL, CHROME ALLOY17 – RACE, C/V JOINT INNER18 – CAGE, C/V JOINT19 – RACE, C/V JOINT OUTER

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AUTION: When removing the spider joint from theripod joint housing, hold the rollers in place on thepider trunions to prevent the rollers and needleearings from falling away.

(3) Slide the interconnecting shaft and spiderssembly out of the tripod joint housing (Fig. 19).

(4) Remove snap ring that retains spider assemblyo interconnecting shaft (Fig. 20). Remove the spiderssembly from interconnecting shaft. If spider assem-ly will not come off interconnecting shaft by hand, it

Fig. 18 Inner Tripod Joint Sealing Boot Clamps1 – SMALL CLAMP2 – LARGE CLAMP3 – INNER TRIPOD JOINT4 – SEALING BOOT5 – INTERCONNECTING SHAFT

Fig. 19 Spider Assembly Joint Removal fromHousing

1 – TRIPOD JOINT HOUSING2 – SPIDER ASSEMBLY3 – SEALING BOOT

can be removed by tapping spider assembly with abrass drift (Fig. 21). Do not hit the outer tripodbearings in an attempt to remove spider assem-bly from interconnecting shaft.

(5) Slide sealing boot off interconnecting shaft.(6) Thoroughly clean and inspect spider assembly,

tripod joint housing, and interconnecting shaft forany signs of excessive wear. If any parts showsigns of excessive wear, the driveshaft assemblywill require replacement. Component parts ofthese driveshaft assemblies are not serviceable.

Fig. 20 Spider Assembly Retaining Snap Ring1 – INTERCONNECTING SHAFT2 – SPIDER ASSEMBLY3 – RETAINING SNAP RING

Fig. 21 Spider Assembly Removal fromInterconnecting Shaft

1 – SPIDER ASSEMBLY2 – DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN

REMOVING SPIDER ASSEMBLY3 – BRASS DRIFT4 – INTERCONNECTING SHAFT

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NSTALLATION

OTE: The inner tripod joint sealing boots areade from two different types of material. High–

emperature applications use silicone rubberhereas standard temperature applications useytrel plastic. The silicone sealing boots are softnd pliable. The Hytrel sealing boots are stiff andigid. The replacement sealing boot MUST BE theame type of material as the sealing boot that wasemoved.

(1) Slide inner tripod joint seal boot retaininglamp, onto interconnecting shaft. Then slide theeplacement inner tripod joint sealing boot ontonterconnecting shaft. Inner tripod joint seal boot

UST be positioned on interconnecting shaft,o the raised bead on the inside of the seal boots in groove on interconnecting shaft (Fig. 22).

(2) Install spider assembly onto interconnectinghaft with chamfer on spider assembly toward inter-onnecting shaft (Fig. 23). Spider assembly must benstalled on interconnecting shaft far enough to fullynstall spider retaining snap ring. If spider assemblyill not fully install on interconnecting shaft byand, it can be installed by tapping the spider bodyith a brass drift (Fig. 24). Do not hit the outer

ripod bearings in an attempt to install spiderssembly on interconnecting shaft.(3) Install the spider assembly to interconnecting

haft retaining snap ring into groove on end of inter-onnecting shaft (Fig. 25). Be sure the snap ring isully seated into groove on interconnecting shaft.

Fig. 22 Sealing Boot Installation on InterconnectingShaft

1 – SEALING BOOT2 – RAISED BEAD IN THIS AREA OF SEALING BOOT3 – GROOVE4 – INTERCONNECTING SHAFT

(4) Distribute 1/2 the amount of grease provided inthe seal boot service package (DO NOT USE ANYOTHER TYPE OF GREASE) into tripod housing. Putthe remaining amount into the sealing boot.

(5) Align tripod housing with spider assembly andthen slide tripod housing over spider assembly andinterconnecting shaft (Fig. 26).

(6) Install inner tripod joint seal boot to intercon-necting shaft clamp evenly on sealing boot.

Fig. 23 Spider Assembly Installation onInterconnecting Shaft

1 – SPIDER ASSEMBLY2 – INTERCONNECTING SHAFT3 – CHAMFER

Fig. 24 Installing Spider Assembly OnInterconnecting Shaft

1 – DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDERASSEMBLY

2 – SPIDER ASSEMBLY3 – INTERCONNECTING SHAFT4 – BRASS DRIFT

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(7) Clamp sealing boot onto interconnecting shaftsing crimper, Special Tool C-4975-A and the follow-

ng procedure. Place crimping tool C-4975-A overridge of clamp (Fig. 27). Tighten nut on crimpingool C-4975-A until jaws on tool are closed completelyogether, face to face (Fig. 28).

AUTION: Seal must not be dimpled, stretched, orut–of–shape in any way. If seal is NOT shaped cor-ectly, equalize pressure in seal and shape it byand.

Fig. 25 Spider Assembly Retaining Snap RingInstalled

1 – INTERCONNECTING SHAFT2 – SPIDER ASSEMBLY3 – RETAINING SNAP RING

Fig. 26 Installing Tripod Housing on SpiderAssembly

1 – TRIPOD JOINT HOUSING2 – SPIDER ASSEMBLY3 – SEALING BOOT

(8) Position sealing boot into the tripod housingretaining groove. Install seal boot retaining clampevenly on sealing boot.

CAUTION: The following positioning proceduredetermines the correct air pressure inside the innertripod joint assembly prior to clamping the sealingboot to inner tripod joint housing. If this procedureis not done prior to clamping sealing boot to tripodjoint housing, boot durability can be adverselyaffected.

Fig. 27 Crimping Tool Installed on Sealing BootClamp

1 – SPECIAL TOOL C-4975A2 – INTERCONNECTING SHAFT3 – CLAMP4 – SEALING BOOT

Fig. 28 Sealing Boot Retaining Clamp Installed1 – CLAMP2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED

COMPLETELY TOGETHER HERE3 – INTERCONNECTING SHAFT4 – SEALING BOOT

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AUTION: When venting the inner tripod jointssembly, use care so inner tripod sealing bootoes not get punctured or, in any other way, dam-ged. If sealing boot is punctured or damaged whileeing vented, the sealing boot can not be used.

(9) Insert a trim stick between the tripod joint andhe sealing boot to vent inner tripod joint assemblyFig. 29). When inserting trim stick between tri-od housing and sealing boot, ensure trim stick

s held flat and firmly against the tripod hous-ng. If this is not done, damage to the sealingoot can occur. If inner tripod joint has a Hytrel

hard plastic) sealing boot, be sure trim stick isnserted between soft rubber insert and tripod hous-ng, and not the hard plastic sealing boot and softubber insert.

(10) With trim stick inserted between sealing bootnd tripod joint housing, position inner tripod jointn driveshaft until correct sealing boot edge to edgeength is obtained for type of sealing boot materialeing used (Fig. 30) (Fig. 31). Then remove the trimtick.(11) Clamp tripod joint sealing boot to tripod joint

sing required procedure for type of boot clamppplication. If seal boot uses crimp type boot clamp,lamp sealing boot onto tripod housing using crimper,pecial Tool C-4975-A. Place crimping tool C-4975-Aver bridge of clamp (Fig. 32). Tighten nut on crimp-ng tool C-4975-A until jaws on tool are closed com-letely together, face–to–face (Fig. 33).

Fig. 29 Trim Stick Inserted for Venting Tripod Joint1 – INNER TRIPOD JOINT SEALING BOOT2 – SEALING BOOT CLAMP3 – INNER TRIPOD JOINT HOUSING4 – TRIM STICK

(12) If seal boot uses low profile latching type bootclamp, clamp sealing boot onto tripod housing usingclamp locking tool, Snap-Ont YA3050 (or an equiva-lent). Place prongs of clamp locking tool in the holesof the clamp (Fig. 34). Squeeze tool together until topband of clamp is latched behind the two tabs onlower band of clamp (Fig. 35).

Fig. 30 Sealing Boot End to End Length with HytrelBoot

1 – 107 MILLIMETERS2 – HYTREL SEALING BOOT3 – SEALING BOOT CLAMP4 – INNER TRIPOD JOINT

Fig. 31 Sealing Boot End to End Length withSilicone Boot

1 – 115 MILLIMETERS2 – SILICONE SEALING BOOT3 – CLAMP4 – INNER TRIPOD JOINT

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(13) Install the driveshaft requiring boot replace-ent back on the vehicle. See Driveshaft Removal

nd Installation in this section for the required drive-haft installation procedure.


1 – CLAMP2 – TRIPOD JOINT HOUSING3 – SPECIAL TOOL C-4975A4 – SEALING BOOT

Fig. 33 Sealing Boot Retaining Clamp Installed1 – CLAMP2 – TRIPOD HOUSING3 – SPECIAL TOOL C-4975A4 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED

COMPLETELY TOGETHER HERE5 – SEALING BOOT
OUTER C/V JOINT SEAL BOOT
REMOVALTo remove outer C/V joint sealing boot from a drive-

haft for replacement, the driveshaft assembly muste removed from the vehicle. See Driveshaft Removalnd Installation in this section for the required drive-haft removal and replacement procedure.(1) Remove driveshaft assembly requiring boot

replacement from vehicle. See Driveshaft Removaland Installation in this section for the required drive-shaft removal procedure.

Fig. 34 Clamping Tool Installed on Sealing BootClamp

1 – CLAMP2 – SPECIAL TOOL YA30503 – SEALING BOOT

Fig. 35 Sealing Boot Clamp Correctly Installed1 – INNER TRIPOD JOINT HOUSING2 – TOP BANK OF CLAMP MUST BE RETAINED BY TABS AS

SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP3 – SEALING BOOT

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(2) Remove large boot clamp retaining C/V jointealing boot to C/V joint housing (Fig. 36) and dis-ard. Remove small clamp that retains outer C/Voint sealing boot to interconnecting shaft and dis-ard. Remove sealing boot from outer C/V joint hous-ng and slide it down interconnecting shaft.

(3) Wipe away grease to expose outer C/V joint andnterconnecting shaft.

(4) Remove outer C/V joint from interconnectinghaft using the following procedure: Support inter-onnecting shaft in a vise equipped with protec-ive caps on jaws of vise to prevent damage tonterconnecting shaft. Then, using a soft–facedammer, sharply hit the end of the C/V joint hous-

ng to dislodge housing from internal circlip on inter-onnecting shaft (Fig. 37). Then slide outer C/V jointff end of interconnecting shaft, joint may have to beapped off shaft using a soft–faced hammer.

(5) Remove large circlip (Fig. 38) from the inter-onnecting shaft before attempting to remove outer/V joint sealing boot.(6) Slide failed sealing boot off interconnecting

haft.(7) Thoroughly clean and inspect outer C/V joint

ssembly and interconnecting joint for any signs ofxcessive wear. If any parts show signs of exces-ive wear, the driveshaft assembly will requireeplacement. Component parts of these drive-haft assemblies are not serviceable.

NSTALLATION(1) Slide new sealing boot to interconnecting shaft

etaining clamp onto interconnecting shaft. Slide the

Fig. 36 Outer C/V Joint Seal Boot Clamps1 – SMALL CLAMP2 – SEALING BOOT3 – OUTER C/V JOINT HOUSING4 – LARGE CLAMP5 – INTERCONNECTING SHAFT

outer C/V joint assembly sealing boot onto the inter-connecting shaft (Fig. 39). Seal boot MUST bepositioned on interconnecting shaft so theraised bead on the inside of the seal boot is ingroove on interconnecting shaft.

(2) Align splines on interconnecting shaft withsplines on cross of outer C/V joint assembly and startouter C/V joint onto interconnecting shaft.

(3) Install outer C/V joint assembly onto intercon-necting shaft by using a soft–faced hammer andtapping end of stub axle (with nut installed) untilouter C/V joint is fully seated on interconnectingshaft (Fig. 40).

Fig. 37 Outer C/V Joint Removal fromInterconnecting Shaft

1 – SOFT HAMMER (TAP HOUSING)2 – WEAR SLEEVE3 – CIRCLIP (OUTER END OF SHAFT)

Fig. 38 Circlip Removal from Interconnecting Shaft1 – SNAP RING PLIERS2 – INTERCONNECTING SHAFT3 – CIRCLIP

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(4) Outer C/V joint assembly must be installed onnterconnecting shaft until cross of outer C/V jointssembly is seated against circlip on interconnectinghaft (Fig. 41).(5) Distribute 1/2 the amount of grease provided in

eal boot service package (DO NOT USE ANYTHER TYPE OF GREASE) into outer C/V jointssembly housing. Put the remaining amount intohe sealing boot.

Fig. 39 Sealing Boot Installation on InterconnectingShaft

1 – SEALING BOOT2 – RAISED BEAD IN THIS AREA OF SEALING BOOT3 – GROOVE4 – INTERCONNECTING SHAFT

Fig. 40 Outer C/V Joint Installation onInterconnecting Shaft

1 – SOFT FACED HAMMER2 – STUB AXLE3 – OUTER C/V JOINT4 – NUT

(6) Install outer C/V joint sealing boot to intercon-necting shaft clamp evenly on sealing boot.

(7) Clamp sealing boot onto interconnecting shaftusing crimper, Special Tool C-4975-A and the follow-ing procedure. Place crimping tool C-4975-A overbridge of clamp (Fig. 42). Tighten nut on crimpingtool C- 4975-A until jaws on tool are closed com-pletely together, face to face (Fig. 43).

Fig. 41 Outer C/V Joint Correctly Installed onInterconnecting Shaft

1 – INTERCONNECTING SHAFT2 – CROSS3 – OUTER C/V JOINT ASSEMBLY


1 – SPECIAL TOOL C-4975A2 – INTERCONNECTING SHAFT3 – CLAMP4 – SEALING BOOT

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AUTION: Seal must not be dimpled, stretched, orut–of–shape in any way. If seal is NOT shaped cor-ectly, equalize pressure in seal and shape it byand.

(8) Position outer C/V joint sealing boot into itsetaining groove on outer C/V joint housing. Installealing boot to outer C/V joint retaining clamp evenlyn sealing boot.(9) Clamp sealing boot onto outer C/V joint hous-

ng using Crimper, Special Tool C-4975-A and the fol-owing procedure. Place crimping tool C-4975-A overridge of clamp (Fig. 44). Tighten nut on crimpingool C-4975-A until jaws on tool are closed completelyogether, face to face (Fig. 45).

(10) Install the driveshaft requiring boot replace-ent back on the vehicle. See Driveshaft Removal

nd Installation in this section for the required drive-haft installation procedure.

Fig. 43 Sealing Boot Retaining Clamp Installed1 – CLAMP2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED

COMPLETELY TOGETHER HERE3 – INTERCONNECTING SHAFT4 – SEALING BOOT


1 – CLAMP2 – TRIPOD JOINT HOUSING3 – SPECIAL TOOL C-4975A4 – SEALING BOOT

Fig. 45 Sealing Boot Retaining Clamp Installed1 – CLAMP2 – TRIPOD HOUSING3 – SPECIAL TOOL C-4975A4 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED

COMPLETELY TOGETHER HERE5 – SEALING BOOT

S

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PECIFICATIONS

ORQUE

DESCRIPTION TORQUEDriveshaft-to-Hub/Bearing

Nut . . . . . . . . . . . . . . . . . . . 244 N·m (180 ft. lbs.)Knuckle-to-Ball Joint

Bolt/Nut . . . . . . . . . . . . . . . . . 95 N·m (70 ft. lbs.)Wheel/Tire-to-Hub/Bearing

Lug Nuts . . . . . . . . . . . . . . . 128 N·m (95 ft. lbs.)

SPECIAL TOOLS

DRIVESHAFT

Boot Clamp Installer C-4975A

Puller 6790

Documents

DIFFERENTIAL AND DRIVELINE - ertyu.org · differential and driveline table of contents page page description and operation front driveshafts .....1 diagnosis and testing driveshaft