Service Manual

Front Wheel Drive
Section (4WD)
Disassembly (Fig. 9)
Note: The inboard and outboard joints are similar in
construction.
The principle difference is the inboard
joint’s outer race has internal ball tracks that are longer,
which allow the shaft of the outboard joint to plunge into
the inboard joint. Also, the inboard joint does not come
with a shaft. The same Assembly and Disassembly
instructions can be used for both joints.
1. Unlock boot clamps securing the boot to the outer
race. Slide boot away from the outer race.
2. Remove retaining ring carefully from the groove in-
side the outer race (Fig. 1
1).
Figure 11
OUTER RACE
RETAINING RING
RETAINING RING
3. Pull cage, ball, and inner race assembly out of the
outer race by pulling on the shaft of the outboard joint
(Fig. 12).
4. Remove snap ring from the outboard shaft. Slide
cage, ball, and inner race assembly of
f the shaft (Fig. 12
and 13).
5. Press all six balls out of the cage. Rotate inner race
so its points are aligned with the center of the cage win-
dows. Pull inner race out of the cage (Fig. 14).
Assembly (Fig. 9)
1. Set cage on a working surface with its tapered side
down. Position inner race into the cage so that the
Figure 12
grooved end faces down and its points are aligned with
the center of the cage windows (Fig. 14).
BALL
CAGE
INNER RACE
SHAFT
SNAP RING
2. Snap all six balls into the cage windows. If the balls
do not stay snapped in place, replace the entire joint
assembly.
3. Slide new boot and boot clamps onto the shaft of the
outboard joint.
Note: T
he cage, ball, and inner race assembly can be
secured onto the shaft in only one position, otherwise
the snap ring will not fit into the groove of the shaft.
Figure 13
4. Grease splines of shaft for the outboard joint. Slide
cage, ball, and inner race assembly onto the shaft. Se-
cure assembly to the shaft with the snap ring (Fig. 12).
5. Grease inside of outer race. Make sure ball tracks
are greased heavily
. Insert cage, ball, and inner race
assembly into outer race (Fig. 11).
6. Install retaining ring carefully into the groove inside
the joint (Fig. 1
1).
7. Make sure joint assembly is completely packed with
grease.
CAGE
WINDOW
Figure 14
8. Slide boot onto the joint. Secure boot to the outer
race and shaft with the boot clamps.
W
orkman 4000 Series Page 10 – 13
Rev. B
Front Wheel Drive Section (4WD)