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Fwd Axle Shafts: Reassembly

WARNING: This page is about a different car, the 1996 Pontiac Grand Prix, 1996 Oldsmobile Cutlass Supreme, 1996 Chevrolet Monte Carlo, 1996 Chevrolet Lumina, and 1996 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. Pack CV joint housing with approximately one-half amount of grease supplied in rebuild kit. Apply remaining grease in boot. Install small clamp and boot on axle shaft (if removed). Slide spacer ring on axle shaft past groove. Slide tripot onto axle shaft. Install tripot in original location (marked during disassembly).
  2. Install tripot retaining snap ring. Slide tripot against snap ring, and install spacer ring in groove. Slide CV joint housing on tripot assembly. Position boot over housing. Remove trapped air using a blunt screwdriver to lift large end of boot off sealed area. See Figure .
  3. Measure length of boot. See Fig 1 . Ensure length is as specified before clamping boots. Move CV joint housing in or out as necessary. When length is within specification, position clamps on boot. Use Boot Clamp Installer (J-35910 ) and torque wrench to install boot clamps.
  4. Tighten large boot clamp to 130 ft. lbs. (176 N.m) and small boot clamps to 100 ft. lbs. (136 N.m). Recheck boot length. To complete reassembly, reverse disassembly procedure.
    Fig 1: Measuring Inner CV Boot Length
    G93A41731Courtesy of GENERAL MOTORS CORP.
    NOTE: Due to complexity of cross-groove type joint construction, disassembly of joint chrome alloy balls and races is not recommended. Replace joint as a complete assembly.


  1. Install small boot clamp and boot onto axle shaft. Ensure retaining ring side of inner race faces axle shaft. Using Boot Clamp Installer (J-35910 ) and torque wrench, tighten small boot clamp to 100 ft. lbs. (136 N.m).
  2. Pack CV joint with one-half amount of grease supplied in rebuild kit. Spread remaining grease evenly in boot. Install new retaining ring in CV joint. Slide CV joint assembly onto axle shaft. Ensure retaining ring seats in groove on axle shaft. Position large end of boot over housing and install boot clamp. Ensure boot lip is located in groove on joint outer race. Boot must not be dimpled, stretched, or out of shape. If necessary to equalize pressure inside boot, use a thin blunt tool (without sharp edges) between boot and joint. Ensure boot length is correct and remove blunt tool. See Figure .
  3. Use Boot Clamp Installer (J-35910 ) and torque wrench to install boot clamps. Tighten large boot clamp to 130 ft. lbs. (176 N.m).


  1. Apply light coat of grease on all mating surfaces. Install small boot clamp and boot on axle shaft. To reassemble inner race, cage and balls, reverse disassembly procedure. See Figure . Ensure retaining ring side of inner race faces axle shaft.
  2. Pack CV joint with one-half amount of grease supplied in rebuild kit. Spread remaining grease evenly in boot. Install new retaining ring in CV joint. Slide CV joint assembly onto axle shaft. Ensure retaining ring seats in groove on axle shaft. Position large end of boot over housing, and install boot clamp.
  3. Use Boot Clamp Installer (J-35910 ) and torque wrench to install boot clamps. Tighten small boot clamp to 100 ft. lbs. (136 N.m) and large boot clamp to 130 ft. lbs. (176 N.m).
  4. Install NEW steel deflector ring (if equipped) with flange toward CV joint. See Fig 1 . Tighten nut until deflector bottoms against shoulder of CV joint outer race.
  5. Install rubber deflector rings (flange toward hub assembly) by stretching ring over housing and seating in groove. To complete reassembly, reverse disassembly procedure.
    Fig 1: Installing Steel Deflector Ring
    G93D41650Courtesy of GENERAL MOTORS CORP.


  1. Install small boot clamp on neck of boot. DO NOT  crimp clamp. Slide boot onto shaft, and position neck of boot in seal groove on axle shaft. Crimp retaining clamp with Boot Clamp Installer (J-35910 ) to 100 ft. lbs. (136 N.m).
  2. Install spacer ring past second groove on shaft. Apply small amount of grease to inside of bearing blocks before assembling. Align flats on opening in bearing block with flats on spider trunnion. Rotate bearing block 90 degrees to secure block to spider. See Fig 1 .
    Fig 1: Installing Bearing Blocks (Trilobal Tripot Type)
    G91F09159Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure counterbored face of spider faces end of shaft.
  3. Slide spider against spacer ring on shaft. Install shaft retaining ring in groove at end of shaft. Slide spider toward end of shaft, and seat spacer ring in groove on shaft. Pack CV joint housing with about one-half amount of grease supplied in rebuild kit. Apply remaining grease in boot.
  4. Place slotted, 6" square metal sheet between boot and bearing blocks to maintain proper bearing block alignment during reassembly. See Fig 2 . Install trilobal tripot bushing in housing. Position large clamp on boot. Slide housing over spider assembly, and remove slotted metal sheet. Slide large end of boot, with clamp in place, over outside of trilobal tripot bushing, and locate lip of boot in groove.
  5. Position joint assembly at 4.9" (125 mm) installed length. Ensuring boot is not dimpled, stretched or out of shape in any way, crimp large diameter retaining clamp with Boot Clamp Installer (J-35910 ) to 130 ft. lbs. (176 N.m).
    NOTE: Ensure boot, housing and clamp remain aligned while crimping.
    Fig 2: Installing Joint (Trilobal Tripot Type)
    G91H09160Courtesy of GENERAL MOTORS CORP.
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