Specifications

Prepare Parts for Reassembly
28 MAINTENANCE MANUAL
Hazard Alert Messages
Read and observe all Warning and Caution
hazard alert messages in this publication. They
provide information that can help prevent seri-
ouspersonalinjury,damagetocomponents,or
both.
WARNING
Topreventseriouseyeinjury,alwayswearsafe
eye protection when you perform vehicle main-
tenance or service.
Solventcleanerscanbeammable,poisonous
and cause burns. Examples of solvent clean-
ers are carbon tetrachloride, and emulsion-type
and petroleum-base cleaners. Read the manu-
facturer’s instructions before using a solvent
cleaner, then carefully follow the instructions.
Also follow the procedures below.
• Wearsafeeyeprotection.
• Wearclothingthatprotectsyourskin.
• Workinawell-ventilatedarea.
• Donotusegasoline,orsolventsthatcontain
gasoline. Gasoline can explode.
• Youmust usehotsolution tanksor alkaline
solutions correctly. Read the manufacturer’s
instructions before using hot solution tanks
and alkaline solutions. Then carefully follow
the instructions.
Take care when you use Loctite® adhesive to
avoidseriouspersonalinjury.Readthemanu-
facturer’s instructions before using this product.
Follow the instructions carefully to prevent ir-
ritation to the eyes and skin.
Clean, Dry and Inspect PartsClean and
Inspect the forks
CAUTION
DO NOT INSTALL A PRESS-ON SHAFT EX-
CLUDER OR POSE™ SEAL AFTER YOU IN-
STALL A UNITIZED PINION SEAL. THE USE
OF A POSE™ SEAL WILL PREVENT COR-
RECT SEATING OF THE UNITIZED PINION
SEAL ON THE FORK AND WILL RESULT IN
LUBRICANT LEAKAGE AT THE SEAL.
The POSE™ seal installation is recommended
only for triple lip and other previous design seals.
Do not use thin metal wear sleeves to refresh
the yoke surface. Wear sleeves pressed onto
the yoke will prevent correct seating of the pin-
ion seal and damage the pinion seal assembly.
Wear sleeve usage will cause the seal to leak
1. Clean the ground and polished surface of
theforkoftheuniversaljointusingaclean
shop towel and a safe cleaning solvent. Do
not use abrasive cleaners, towels or scrub-
berstocleantheforkorangesurface.Do
not use gasoline.
NOTE:
The unitized seal features a rubber inner
sleeve that is designed to seal and rotate
with the fork. This feature allows you to re-
use a fork with minor grooves.
2. Inspect the fork seal surface for grooves.
• Ifyoundgroovesonforkhubsusedwithsin-
gle or triple-lip seals: Replace the yokes
• Ifyoundgroovesontheforkhubsusecali-
pers to measure the groove diameters. If any
groove diameter measures less than the di-
mensions shown in Figure 4.1, replace the
yoke.
Figure 4.1
A - MINIMUM GROOVE DEPTH — DIAMETER
B - FORKE SEAL DIAMETER
UNITIZED PINION SEAL (UPS)
fork Seal
Diameter
Minimum fork Diameter at
Groove (Inches)
76,200 / 76,237
82,550 / 82,677
75,946
82,296