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Axle Shaft Outer Joint & Seal: Disassembly

WARNING: This page is about a different car, the 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Due to the helical splines on the axle shaft bar, disassembly and assembly of the joints will be difficult. Follow the instructions provided.
  1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the large seal retaining clamp. Remove the small seal retaining clamp from the axle shaft bar with a side cutter and discard.
  2. Separate the CV joint seal from the CV joint race at the large diameter. Slide the seal away from the joint along the axle shaft bar. Wipe the grease from the face of the CV joint inner race.
  3. Before removing the CV joint assembly from the axle shaft bar, perform the following procedure:
    1. Choose a reference mark on the axle shaft bar.
    2. Measure the distance between the reference mark and the face of the CV joint inner race. Make a note of this measurement. The measurement is.
    3. Mark the inboard side (toward the center of the axle shaft bar) of the CV joint inner race as a reference.
    4. Inspect the CV joint inner race/axle shaft bar interface for the presence of a retaining ring. If present, remove the retaining ring using Snap Ring Pliers (J 8039-A).
  4. Clamp the axle shaft into a vise. Attach the CV Puller (J 41398) to the threaded area of the outer race.
  5. Attach Slide Hammer Assembly (J 2619-01) onto the outer end of the CV puller. Use the slide hammer assembly to remove the CV joint from the axle shaft bar. Remove slide hammer assembly and CV puller from the CV joint.
    CAUTION: Never reuse the retaining ring.
  6. Remove the retaining ring from the axle shaft bar. Discard the retaining ring. Remove the CV joint seal from the axle shaft bar.
  7. Place a brass drift against the CV joint cage. See Fig 1 . Tap gently on the brass drift with a hammer in order to tilt the cage. Remove the first chrome alloy ball when the CV joint cage tilts.
  8. Tilt the CV joint cage in the opposite direction to remove the opposing chrome alloy ball. Repeat this process to remove all 6 of the balls.
  9. Pivot the CV joint cage and the inner race 90 degrees to the centerline of the outer race. At the same time, align the cage windows with the lands of the outer race. Lift out the cage and the inner race.
  10. Remove the inner race from the cage by rotating the inner race upward. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. Dry all the parts.
  11. Check the CV joint assembly for unusual wear, cracks, or other damage. Replace any damaged parts. Clean the axle shaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
Fig 1: Disassembling Outer CV Joint (Rzeppa Type)
G95H13406Courtesy of GENERAL MOTORS CORP.
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