GM 26059677
Inner CV Joint, Front

To service and repair the constant velocity joint boot, namely the wheel drive shaft outer joint and replacing the seal, we will need: snap ring pliers (J 8059), drive axle seal seal clamp pliers (J 35910), and drive axle swage ring clamp (J 41048). Start by mounting the halfshaft into a vise, applying protective covers to the jaws. If you are using a hand grinder, first use it to cut through the swage rings without hurt the outer race of CV Joint, then use seal compress on the halfshaft from the side of CV Joint outer race. Clean all grease off the CV Joint face and get the halfshaft retaining snap ring from the inner race. Use snap ring pliers (J 8059) to spread the snap ring ears and remove CV Joint from the halfshaft. Discard the old seal and then use a brass drift to tilt the cage and pull out all balls. Turn the cage and inner round 90 degrees to it lining up with the outer round, pull them out and degrease all parts. Check for the wear or damage, and clean the halfshaft bar with the wire brush. For assembly, confirm that parts are in good condition, grease the inner and outer race grooves, and place the inner race in the cage. Align and rotate the inner race down ward and then insert the cage and inner race in the outer race. Use a brass drift to tilt the cage and reintroduce all balls. Pack the CV Joint seal and assembly using the pre-measured amount of grease and then bring the brand new small sized swage clamp up to the CV Joint seal and the large retaining clamps on the seal as well. Put the small end of the CV Joint seal into the groove of the junction seal on the halfshaft bar and align and tighten the swage clamp using drive axle swage ring clamp (J 41048). Tighten the bolts by hand until they are tight and secure the alignment of the seal, halfshaft bar and swage clamp, and tighten each bolt in a 180 degree turn using a ratchet wrench. Once the bolts are loosened up and the dies are separated, locate any deformities with the swage clamp and reinsert where necessary. Place the retaining snap ring in the inner race face of the retaining ring side of the CV Joint before inserting the halfshaft bar. Slide the CV Joint onto the halfshaft bar, make sure it engages and set the large diameter of the CV Joint seal over the CV Joint outer race. Secure retaining clamp to housing using drive axle seal clamp pliers (J 35910), breaker bar, and torque wrench and tighten to 176 n.m (130 lb ft) with clamp ear gap dimension check.

Start the wheel drive shaft inner joint and seal replacement by collecting the following tools: Swag Clamp Tool (J 41048), Drive Axle Seal Clamp Plier (J 35566) and Snap Ring Pliers (J 8059). Work with Swag Clamp Tool (J 41048) along with Drive Axle Seal Clamp Plier (J 35566) and Snap Ring Pliers (J 8059). Use side cutters to remove the clamp from the boot but take care to avoid damaging the tripot housing. A hand grinder should cut through the swag ring before you remove the tripot housing along with the tripot tri-lobal bushing from the halfshaft bar. The cleaning process should remove all traces of lubricants from both the housing and spider assembly while you dispose of the tripot tri-lobal bushing. The transmission sealing surface requires preparation with 320 grit 3M cloth to remove corrosion until components dry completely while proper handling of the tripot spider assembly avoids tripot ball and needle roller separation. Bind the tripot boot around the halfshaft bar while using tool J8059 to disperse the spider assembly's spacer rings . Professional cleaning of the halfshaft bar with a wire brush reveals damage to the needle bearings, needle rollers and trunnion components. Discard the tripot boot together with the spacer rings before inspection. When components exhibit damage it is essential to replace those faulty parts. To install the new swage clamp place it on the boot neck without swaging it before adding the new small swage clamp and boot in their proper position on the halfshaft bar. Swage the boot clamp using J 41048 on the halfshaft bar while making sure the boot neck sits within the bar's groove. Evolve slowly tighten the bolts by hand before achieving a snug fit while matching the boot alignment with the halfshaft bar and swage clamp. Finish the installation by using a ratchet wrench to torque each bolt at 180 degrees intervals. Inspect the sunken areas in the clamp if present before re-swaging the clamp. Review the swage clamp for "lip" deformities before confirming the correct positioning of the boot convolute retainer to capture four convolutions. Sitting installation of the spacer ring together with spider assembly onto halfshaft bar while inserting the second spacer ring into the groove at the halfshaft bar's terminal. Verify proper seating of all rings. Put the pre-packaged grease from the kit into the boot and housing space while clamping the large retaining clamp to the boot and mounting the housing together with the new tripot tri-lobal bushing onto the spider assembly . Check the inboard stroke position on the tripot tri-lobal bushing before you install the boot then secure the large retaining clamp and boot to the housing using J 35566 while still removing the convolute retainer from the boot.

To service and repair the Axle Shaft assembly, namely the wheel drive shaft inner joint and boot replacement; the following (list of) tools are required: swag clamp tool (J 41048), drive axle seal clamp plier (J 35566), and snap ring pliers (J 8059) were the 3 items of disc brake consumer products that I chose to be included in the showroom inventory. Start by disassembling the clamp from the boot using the side cutters without harming the tripot housing. Grind using a hand grinder to cut through swag ring, then withdraw the tripot housing and the tripot tri-lobal bushing from the halfshaft bar. Degrease the housing and spider assembly completely, disposing of the tripot tri-lobal bushing. Apply 320 grit of 3m cloth to remove any corrosion on the transmission sealing surface and let the housing and spider assembly dry. Apply cautious handling to the tripot spider assembly to avoid separation of tripot balls and needle rollers. Compress the tripot boot onto the halfshaft-bar, snap ring plier (J 8059) to widen spacer ring spacing and eliminate the spider assembly, also the spacer ring, spider assembly and second spacer ring and tripot boot. Discard the tripot boot and spacer rings, clean half-shaft bar with wire brush and inspect needle bearings, needle rollers and trunnion for any damage. Replace any damaged parts. To assemble, locate the new swage clamp up on the neck of the boot without swaging, then slide the new small swage clamp and boot to the precise location on half shaft bar. Make sure the neck of the boot is in the boot groove on the halfshaft bar; and swage the clamp, using the swag clamp tool (J 41048) with the alignment and securing of the parts. Hand tighten the bolts until snug, making sure that there are no pinch points on the boot. Turn the bolts alternately 180 degrees off with a ratchet wrench until both sides hit bottom, then back off the bolts and split the dies. Should there be deformities in the swage clamp, then insert into j 41048 and re-swage. Examine for any "lip" deformation and confirm that the convolute retainer has been assembled correctly so that there is no damage to the boot. Mount the convolute retainer over the boot for four convolutions, then mount the spacer ring and spider assembly on the halfshaft bar, and the other spacer ring into the groove at the end of the halfshaft bar making sure all rings fit into the grooves. After the pre-measured grease from the kit is packed into the boot and housing, the large retaining clamp must be placed on the boot and pack the housing and new tripot tri-lobal bushing over the spider assembly. Place the boot on the tripot tri-lobal bushing, inspect the inboard stroke position for the male tripot housing assembly (dimension a = '11.02 inches') or female tripot housing assembly (dimension b = '8.98 inches'), secure the large retaining clamp and boot to the housing using 'drive axle seal clamp plier(J 35566) and finally, remove the convolute retainer off the boot.

Use side cutters to detach the boot clamp before starting the wheel drive shaft inner joint and seal exchange. A hand grinder should be used to cut through the swage ring while you carefully discard the tripot housing and trilobal tripot bushing from the halfshaft bar. After complete cleaning of the housing and spider assembly discard the tripot bushing. The transmission sealing surface should receive treatment using a 3M cloth with 320 grit abrasiveness or its equivalent to remove corrosion while the housing and spider assembly dries. The necessary manipulations for assembling the tripot spider require gentle movements to keep the tripot balls and needle rollers in place. Cut a piece of tripot boot to fit on the halfshaft bar until snap ring pliers (J 8059) apply the proper tension to the spacer rings so assembly removal can begin. Operate a wire brush to clean the halfshaft bar while you inspect all components for damage. Replace any broken parts with proper replacement items from the kit. First position the new swage clamp on the boot neck before applying swaging pressure while placing the new small swage clamp and boot into their final position on the halfshaft bar. Swage the clamp using J 41048 swage clamp tool (J 41048) by aligning both swage clamp halves onto the boot neck in the halfshaft bar's groove. Manually tighten bolts until they become snug but confirm there are no dangerous indentations on the boot. When using a ratchet wrench to tighten the bolts do 180-degree turns until every side bottoms out then relax tension between the dies for separation. Deformities in the swage clamp require the tool (J 41048) for re-swaging the clamp. Before installing the convolute retainer verify the swage clamp's "lip" integrity by checking the assembly position as improper installation may damage the boot. Before installation place the convolute retainer over the boot while keeping four convolutions inside while making sure rings completely engage their seating positions. Place the spacer ring and spider assembly on the halfshaft bar before setting the other spacer ring into its groove on the bar's end while ensuring complete insertion. Apply pre-measured kit grease to fill the boot and housing before putting the large retaining clamp onto the boot. Set the housing along with its new trilobal tripot bushing above the spider assembly before boot installation onto the bushing. Complete the inboard stroke setup by tightening the large retaining clamp to the housing with drive axle seal clamp pliers (J 35566) and removing the convolute retainer from the boot .

To replace the front wheel drive shaft outer joint and seal, collect the necessary: j 35910 seal clamp tool (J 35910), j 41048 swage clamp tool (J 41048), j 8059 snap ring pliers (J 8059). Start by clamping the halfshaft in a vise with covers on the jaws. Cut with a hand grinder and make slow cuts around the swage rings being careful as not to damage outer race. Compress seal away from CV Joint outer race and clean off all grease on CV Joint face. Find the halfshaft retaining snap ring in the inner race, and while holding the j 8059 to spread the snap ring ears, there is time to pull the CV Joint off of the halfshaft. Dispose of the old seal and after that use a brass drift in sliding the cage to the side and remove the balls. Following the proper degreasing of all CV Joint parts, look for wear or damage. Apply a light coat of grease around and into the inner and outer race grooves, then place the inner race into the cage and align it to the outer race. Remove the balls and tilt the cage by using brass drift. Pack the CV Joint seal and assembly with the pre-measured grease out of the kit and then apply the new small swage clamp on the CV Joint seal and the large retaining clamp. With j 41048, align and secure the swage clamp, tightening the bolts as one does in an alternating manner till they are tightened but not too tight. Make sure to align the seal, halfshaft bar and swage clamp and tighten balts 180 degrees each time. Having loosened the bolts and separated the dies, inspect the swage clamp for deformities. Check that the CV Joint inner race has the retaining ring side facing the halfshaft bar before installing the retaining snap ring into the CV Joint inner race. Sandwich the CV Joint between the halfshaft bar, ensure engagement, and dress the large diameter CV Joint seal on the outer race. Secure the large retaining clamp to the housing by using j35910 breaker bar and a torque wrench while torquing it in to 176nm (130 ftlbs) and finally to check upon the gap dimension on the clamp ear.

Use the Drive Axle Swage Ring Clamp Tool (J41048) to align and secure the swage clamp, tightening the bolts alternately until snug.

J 41048 Swage Clamp Tool, J 35566 Drive Axle Seal Clamp Plier, and J 8059 Snap Ring Pliers.

Slide the large diameter of the CV joint boot over the CV joint outer race and clamp it tightly using the Drive Axle Clamp Swage Tool (J 36652), ensuring proper alignment and tightening the bolts until both halves of the tool touch.

Swage Clamp Tool (J 41048), Drive Axle Seal Clamp Plier (J 35566), and Snap Ring Pliers (J 8059).

Tighten the bolts by hand until snug, then align the boot, halfshaft bar, and swage clamp, tightening each bolt 180 degrees at a time with a ratchet wrench.

Insert the halfshaft assembly into J 41048, align the swage clamp, and tighten the bolts alternately until snug.

Locate the halfshaft retaining snap ring in the inner race, spread its ears using J 8059, and then remove the CV joint.

Thoroughly degrease the CV joint parts and inspect for damage.

Handle the tripot spider assembly with care to prevent separation of the tripot balls and needle rollers.

Assemble the joint with the convolute retainer in the correct position, capturing four convolutions, and install the spacer ring and spider assembly onto the halfshaft bar, followed by the other spacer ring in the groove at the end of the halfshaft bar.

Place the new small retaining clamp onto the outer seal.