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Drive Shaft and Axle

TJ Joint Repair Procedures

In this manual: Drive Shaft and Axle
General Information — 15Maintenance — 7Engine Mechanical System — 84Engine Electrical System — 49Emission Control System — 22Fuel System — 95Clutch System — 28Manual Transmission — 21Dual Clutch Transmission (DCT) System — 47Drive Shaft and Axle — 20Suspension System — 36Steering — 23Restraints — 39Brake System — 54Body (Interior and Exterior) — 209Body Electrical System — 254Heating, Ventilation, and Air Conditioning — 56
18steps
~118min
5/5difficulty
2special tools
Done 0 of 18

Replacement

  1. Remove the front drive shaft. (Refer to Drive Shaft Assembly - "Front Drive Shaft")
  2. Remove the joint case snap ring (B) from the drive shaft spline (A).
  3. Remove both clamps from the TJ case.
  4. Remove the TJ case (A).
  5. Remove the snap ring (A) from the shaft.
  6. Remove the spider assembly (B) from the driveshaft (A) using the special service tool (09495-33000).
  7. Clean the spider assembly.
  8. Remove the TJ boot (A).

Inspection

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

Installation

  1. Wrap tape around the TJ driveshaft splines to prevent damage to the boot.
  2. Using the alignment marks (D) made during disassembly, install the spider assembly (A) and snap ring (B) onto the driveshaft splines (C).
  3. Add the specified grease to the joint boot in the amount that was wiped off during inspection.
  4. Install both boot bands.
  5. To control the air in the TJ boot, observe the specified distance between the boot bands when they are tightened.
    Engine TM Distance (D) mm (in.)
    Left side Right Side
    Gamma 1.4 MPI 6 M/T 545,9 (214921) 826,2 (32,5275)
    Gamma 1.6 GDI/MPI 6 M/T 545,9 (214921) 826,2 (32,5275)
    Gamma 1.6 MPI 6 A/T 522,8 (20,5826) 814,6 (32,0708)
    Gamma 1.6 GDI 6 DCT 493,3 (19,4212) 878,8 (34,5984)
    U-II 1.4 T-GDI 6 M/T 546,1 (21,5000) 826,4 (32,5354)
    U-II 1.6 TCI 6 M/T 540,1 (21,2637) 832,4 (32,7716)
    U-II 1.6 TCI 6 A/T 523,0 (20,5905) 814,7 (32,0747)
    Gamma 1.6 T-GDI 6 M/T 517,9 (20,3897) 530,6 (20,8897)
    Kappa 1.0 T-GDI 6 M/T 572,2 (22,5275) 800,5 (31,5157)

  6. Using the SST (09495-3K000), secure the TJ boot clamps.

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

  7. Install the front drive shaft. (Refer to Driveshaft Assembly - "Front Drive Shaft")

Test yourself

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