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Axle Shaft Outer Joint & Seal: Reassembly

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.
  1. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race. See Figure . Hold the inner race 90 degrees to the centerline of the cage with the lands of the inner race aligned with the windows of cage. Insert the inner race into the cage.
  2. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows with the lands of the outer race.
    NOTE: Ensure that the inner race is oriented the same as prior to disassembly. Use the reference mark placed earlier.
  3. Install the cage and the inner race into outer race. Place a brass drift against the CV joint cage. Tap gently on the brass drift with a hammer in order to tilt the cage. Install the first chrome alloy ball when the CV joint cage tilts. Repeat this process to install all six of the balls.
  4. Pack the CV joint with half of the grease supplied in the service kit. Install the NEW small retaining clamp on the neck of the seal. DO NOT crimp. Clean the axle shaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
  5. Slide the CV joint seal onto the axle shaft bar. Expose the reference mark by sliding the CV joint seal up the axle shaft bar toward the tripot end.
  6. Position the large seal retaining clamp around the joint seal. Place the NEW retaining ring onto the axle shaft bar. While supporting the tripot assembly, place the axle shaft assembly onto the arbor press with the CV assembly under the press head.
  7. Lower the arbor press head onto the CV joint assembly until the press cannot move any further. This ensures that the retaining ring engages in the inner race. DO NOT exceed 4000 Lbs., press load during assembly. Remove the axle shaft assembly from the arbor press.
  8. Measure the distance between the reference mark on the axle shaft bar and the face of the CV joint inner race. Compare the mark with the measurement made before disassembly. Repeat the previous four steps if the current measurement does not match the measurement made before disassembly.
  9. Place the neck of the CV joint seal into the seal groove on the axle shaft bar.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
    NOTE: Check the clamp position during the crimping operation in order to ensure the clamp is positioned correctly around the entire circumference.
  10. Crimp the small retaining clamp by using Drive Axle Seal Clamp Pliers (J 35910), a breaker bar, and a torque wrench. Tighten the seal retaining clamp to specification. See TORQUE SPECIFICATIONS  .
  11. Check the gap dimension. Continue tightening until the gap dimension is reached. Place the remaining grease from the service kit inside the seal.
  12. Measure approximately 0.6875" (17.5 mm) up from the bottom edge of the CV outer joint assembly. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of CV joint.
    NOTE: The CV joint seal must not be dimpled, stretched or out of shape in any way. If seal is not shaped correctly, equalize pressure in the seal and shape the seal properly by hand.
  13. Locate the seal lip to the ridge of the CV outer joint assembly as measured in the previous step.
  14. Crimp seal retaining clamp with drive axle seal clamp pliers, a breaker bar, and a torque wrench. See Figure . Tighten seal retaining clamp to specification. See TORQUE SPECIFICATIONS  .
  15. Check the gap dimension. Continue tightening until 0.15" (3.9 mm) gap is achieved.
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