TJ Joint Repair Procedures

Removal

1. 1
   Remove the front drive shaft. (Refer to Drive Shaft Assembly - "Front Drive Shaft")
2. 2
   Remove the joint case snap ring (B) from the drive shaft spline (A).

   

3. 3
   Remove both clamps from the TJ case.

   

   

4. 4
   Remove the TJ case (A).

   

   

5. 5
   Remove the snap ring (A) from the shaft.

   

6. 6
   Remove the spider assembly (B) from the drive shaft (A) using special service tool (09495-33000).

   

7. 7
   Clean the spider assembly.
8. 8
   Remove the TJ boot (A).

   

Inspection

1. 1
   Inspect the spider assembly for roller rotation, wear, or corrosion.
2. 2
   Inspect the groove inside the joint case for wear or corrosion.
3. 3
   Inspect the TJ boot for damage and wear.

Installation

1. 1
   Wrap tape around the drive shaft (TJ) spline to prevent damage to the boot.
2. 2
   Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and snap ring (B) onto the splines of the drive shaft (C).

   

   

3. 3
   Add the specified grease to the joint boot in the amount that was wiped off during inspection.
4. 4
   Install both boot bands.
5. 5
   Using the SST (09495-3K000), secure the TJ boot clamps.

   Clearance (A): 2.0 mm (0.0787 in) or less

   

6. 6
   Install the front propeller shaft. (Refer to Drive Shaft Assembly - "Front Drive Shaft")
7. 7
   Check the front alignment. (Refer to Suspension System - "Front Wheel Alignment")