Axle Shaft Inner Joint & Boot: Reassembly
WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
- Install the NEW small boot retaining clamp on the neck of the boot. DO NOT crimp the small boot retaining clamp. Clean the axle shaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
- Slide the tripot boot and clamp onto the axle shaft bar, passing the seal grooves of the axle shaft bar toward the CV end of the axle shaft bar.NOTE: Ensure that the spacer ring is next to the shoulder of the axle shaft bar before installing the tripot spider.
- Place the new spacer ring next to the shoulder on the axle shaft bar. Place the tripot spider assembly onto the axle shaft bar.
- Place the axle shaft assembly onto the arbor press. The tripot spider assembly must be on the press plate. The CV joint assembly must be under the press head. See Fig 1 .
- Lower the arbor press head onto the CV joint assembly until the tripot spider is next to the spacer ring. DO NOT exceed 4000 Lbs. press load during assembly. Remove the axle shaft assembly from the arbor press.
- Place the NEW spacer ring on the axle shaft bar groove at the end of the axle shaft bar.
- Slide the tripot boot to the corresponding groove on the axle shaft bar. Crimp the small boot retaining clamp using drive axle boot clamp pliers, a torque wrench, and a breaker bar. Place approximately one quarter of the grease from the service kit in boot. Use the remainder to repack the housing.
- Install the NEW trilobal tripot bushing to housing. Ensure the bushing is flush with the face of the housing. Slide the housing over the spider assembly on the axle shaft bar.NOTE: The end of the inboard boot must be next to the seal stop on the trilobal tripot bushing.
- Position the large boot retaining clamp around the inboard boot. Engage the inboard boot.NOTE: The axle shaft inboard boot must not be dimpled, stretched out or out of shape in any way. If the axle shaft inboard boot is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing to equalize the pressure. Shape the axle shaft inboard boot properly by hand. Remove the thin, flat, blunt tool.
- Position joint assembly at the proper vehicle dimension. See Fig 2
.
- For vehicles with 2.2L engines and automatic transmissions, dimension "a" is 3.5" (90 mm).
- For all other vehicles, dimension "a" is 4.5" (115 mm).
- Align the axle shaft inboard boot, housing and large clamp while latching.
- Latch the boot retaining clamp using drive axle boot clamp pliers if the clamp is earless or crimp the boot retaining clamp using drive axle boot clamp pliers if the joint uses an eared clamp. See Fig 3 . Stroke the joint to full extension and compression several times to distribute the grease.