Document ID: 2845748

Special Tools

CH 48894 - Drive Axle Seal Clamp Pliers
J 35910 - Drive Axle Boot Clamp Pliers

For equivalent regional tools, refer to Special Tools.

Disassemble Procedure

Note: The inner constant velocity (CV) joint assembly and the internal parts are not serviceable. If the CV joint is found to have excessive wear or damage, replace the wheel drive shaft as an assembly. Also, the right wheel drive shaft inner boot is not serviceable on vehicles with raised bar design shaft.

Remove the wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement.
Remove the outer CV joint and boot. Refer to Rear Wheel Drive Shaft Outer Joint and Boot Replacement.

Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

Using the appropriate tool, remove and discard the outer boot clamp (3) and the inner boot clamp (2) from the CV joint (4).

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Note: If the boot is damaged and either water or other foreign material are found in the CV joint, replace the wheel drive shaft as an assembly. The inner CV joint is NOT SERVICED.

Remove the CV joint boot (2) from the CV joint (3) and the wheel drive shaft (1).

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Note: If the ball bearings for the CV joint have a dull surface on them, replace the wheel drive shaft as an assembly. The inner CV joint is NOT SERVICED.

Using the appropriate cleaner, remove the lubricant from the CV joint and the wheel drive shaft.

Assemble Procedure

Install the CV joint boot and clamp (1) on the wheel drive shaft and CV joint housing (2).

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Ensure that the CV joint boot (1) is properly seated in the groove (2) in the wheel drive shaft (3).

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Using the J 35910 - pliers , breaker bar, torque wrench and or ratchet (1), close the clamp (2) until the gap (3) measures 1.8 mm (0.07 in).

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Place approximately half of the lubricant (1) in the CV joint boot (2) and the other half in the CV joint (3).

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Install the CV joint boot and clamp (2) CV joint housing (1).
The following service procedure is for those vehicles equipped with the ear type boot clamp (2). For those vehicles equipped with the earless type (low profile) (1), proceed to step 8

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Using the J 35910 - pliers (3), breaker bar (5) and a torque or racket wrench (4), close the clamp until the gap measures 1.9 mm (0.07 in).

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Note: Ensure that the boot clamp is securely closed and seated properly on the boot.

Using the CH 48894 - pliers (1), close the boot clamp (3).

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Move the CV joint in a circular motion to distribute the lubricant inside the cv joint housing.
Clean any remaining lubricant from the outside of the CV joint.
Install the outer CV joint and boot. Refer to Rear Wheel Drive Shaft Outer Joint and Boot Replacement.
Install the wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement.

Document ID: 2845745

Special Tools

CH 48894 - Drive Axle Boot Clamp Pliers
J 8059 - Snap Ring Pliers
J 35910 - Drive Axle Boot Clamp Pliers

For equivalent regional tools, refer to Special Tools.

Disassemble Procedure

Note: For vehicles equipped with RPO (ZL1), the wheel drive shaft joints are not serviceable, replace wheel drive shaft.

Remove the wheel drive shaft from the vehicle. Refer to Rear Wheel Drive Shaft Replacement.
Install the wheel drive axle shaft in a soft jawed vice.

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Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

Note: The following proceed is for the wheel drive shaft that have the low profile boot clamp. If the wheel drive shaft is equipped with the ear type boot clamp, proceed to step 6.

Using the appropriate tool, remove and discard the outer boot clamp (2) from the CV joint boot (3).

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Using a pair of side cutters, remove and discard the inner boot clamp (4) from the CV joint boot (3).
Remove the CV joint boot (3) from the CV joint housing (1).
Using a pair of side cutters, remove and discard the outer boot clamp (3) and the inner boot clamp (1).

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Remove the CV joint boot (2) from the CV joint housing (4).
Using a hammer and a block of wood, remove the CV joint (2) from the wheel drive shaft (1).

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Using the J 8059 - pliers , remove the retaining ring (2) from the wheel drive shaft.

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Remove the CV joint boot (1) from the wheel drive shaft (2).

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Inspect the wheel drive shaft CV joint. Refer to Wheel Drive Shaft Outer Joint Inspection.

Assemble Procedure

Note: DO NOT crimp the boot clamp at this time.

Position the boot and the clamp (1) on the wheel drive shaft (2).

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Ensure that the boot (1) is properly seated in the groove (2) in the wheel drive shaft (3).

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Using the J 8059 - pliers , install the retaining ring (2) on the wheel drive shaft (1).

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Using the J 35910 - drive axle boot clamp pliers (1), close the boot clamp (2) until the gap (3) measures 2.15 mm (0.85 in).

Note: The CV joint should just touch the inner retaining ring.

Using a block of wood and a hammer, install the CV joint (1) on the wheel drive shaft.

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Place approximately half of the lubricant (2) inside the CV boot (1) and other half in the CV joint (3).

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Remove any excess lubricant on the CV joint housing or the boot.
If working with a wheel drive that has the ear type clamp (2), proceed to step 9. If the wheel drive shaft has the low profile clamp (1), skip step 9 and proceed to step 10.

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Note: When measuring the clamp end gap dimension, the gap should not exceed 2.15 mm (0.85 in).

Using the J 35910 - pliers (1), torque or ratchet wrench and breaker bar, close the boot clamp until the gap (3) measures 2.15 mm (0.85 in).

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Note: Ensure that the locking tabs on the clamp are fully locked in place.

Using the CH 48894 - pliers (1), close the boot clamp (3).

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Move the CV joint in a circular motion 4 to 5 times to distribute the lubricant.
Remove the wheel drive shaft from the vise.
Install the wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement.

Operation	Task	Skill	Hours
Replace	Rear Axle · One Side	B	2.4
Replace	Rear Axle · One Side · NOTE · To R&R Axle Shaft Seals, Add · Each	B	0.2
Replace	Rear Axle · Both Sides	B	4.5
Replace	Rear Axle · Both Sides · NOTE · To R&R Axle Shaft Seals, Add · Each	B	0.2

Constant Velocity Joint Boot