OVERHAUL

1. Remove the halfshaft.
2. Remove the inboard joint boot clamps.

   Fig. 1:Removing the outer band from the CV-boot

3. Clean the joint before removing the boot.

   Fig. 2:Clean the CV-joint housing prior to removing boot

4. Slide the inboard joint boot toward the outboard joint.
5. Place matchmarks on the inboard joint tulip and the shaft. Remove the inboard joint tulip from the driveshaft.

   Fig. 3: Place matchmarks on the inboard joint outer race and shaft

6. Clamp the driveshaft in a vise. Using a snapring expander, remove the snapring and disassemble the tripod joint.
7. Using a brass bar and hammer, remove the tripod joint from the driveshaft. Do not punch the roller.

   Fig. 4: Use snapring expanders to extract the snapring from the end

   Fig. 5: With a brass bar and hammer, tap the joint hard enough to remove

8. Remove the inboard joint boot.
9. Remove the outboard joint boot clamps and boot. Do not disassemble the outboard joint.

   To install:

10. Temporarily install the new boot and new boot clamps to the outboard joint.

    NOTE: Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.

11. Temporarily install the new boot and the new boot clamps for the inboard joint to the driveshaft.
12. Assemble the tripod joint.
    1. Place the beveled side of the tripod axial spline toward the outboard joint.
    2. Align the matchmarks placed before disassembly.
    3. Using a brass bar and hammer, tap in the tripod joint onto the driveshaft. Do not punch the roller.
13. Using a snap ring expander, install a new snapring.
14. Before assembling the boot to the outboard joint, pack the boot with grease. Usual capacity is 4.2–4.6 oz. (120–130 g).

    NOTE: Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.

15. Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. Usual capacity is 7.6–7.9 oz. (215–225 g).
16. Align the matchmarks on the outer race and shaft, then install the outer race.
17. Install the boot to the inboard joint.

    NOTE: Be sure the boot is on the shaft groove and inboard joint outer race groove. Install the boot without twisting it.

18. Set the length of the shaft to the following:
    • 1991 models — 19.41–19.81 inch (493–502mm)
    • 1992–97 models — 19.146–19.546 inch (486.4–496.41mm)

      Fig. 6: Set the length of the driveshaft at the points shown here

19. Insatall the two clamps to the inboard joint boot. Bend back the band and lock it.
20. Install the halfshaft.