Tracker Off-Road 800SX Service Manual page 152

NOTE: The boot is positioned correctly when the

small end of the boot seats down into the recessed
groove.
2. Using the boot clamp tool, secure the small clamp of
the inner boot.
MOD516A
3. Apply 100 grams (2/3 of contents) of grease from the
pack into the bearing housing.
4. Check the condition of the circlip on the end of the
half shaft and replace if necessary. Engage the exter-
nal splines on the end of the half shaft into the star-
shaped inner race of the CV joint; then grasp the half
shaft and seat it into the CV joint assembly by press-
ing it firmly into the CV joint assembly.
 NOTE: A light tap with a hammer might be
required.
MOD517
5. Using the boot clamp pliers, install the large diame-
ter boot clamp.
MOD514
150
MOD518
NOTE: Steps 1-5 can be used to replace the out-

board boot.
NOTE: In the outboard boot, use the final 55 grams

(1/3 of contents) of grease from the pack in the bear-
ing housing.
INSTALLING REAR DRIVE AXLE
 NOTE: It is recommended to apply grease on the
splines for the rear drive axles going into the tran-
saxle. Prior to installing verify the location of the O-
ring for the rear drive axles.
1. Push the axle shaft (A) into the inner CV joint hous-
ing (B) to release the lock ring; then while the axle
shaft and the inner CV joint housing are pushed
together slide the drive axle into place in the gear
case.
MOD350
NOTE: To ensure proper axle seating, give it a light

pull; the axle should remain "clipped" in place.
2. Swing the knuckle up and onto the drive axle; then
place the knuckle into place in the upper A-arm.
Secure the knuckle to the A-arm with cap screws and
new lock nuts. Tighten to 45 ft-lb (61.2 N-m).
3. Install the hubs (see Hub/Brake Disc in this section).
4. Install the wheels and using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre-
ments to a final torque of 100 ft-lb (136 N-m).
5. Remove the vehicle from the support stand and
release the parking brake.