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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Wheel Drive Shafts) >> Repair Instructions >> Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the new small seal retaining clamp on the neck of the seal.
  2. Do not crimp the small seal retaining clamp.
  3. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
  4. Slide the tripot seal and clamp onto the halfshaft bar, passing the seal grooves of the halfshaft bar toward the CV end of the halfshaft bar.
    IMPORTANT: Ensure that the spacer ring (1) is next to the shoulder of the halfshaft bar before installing the tripot spider (3).
  5. Place the new spacer ring (1) next to the shoulder on the halfshaft bar.
    Fig 1: View Of Tripot Spider Assembly
    GM256120Courtesy of GENERAL MOTORS CORP.
  6. Place the tripot spider assembly (3) onto the halfshaft bar.
  7. Place the halfshaft 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.
    Fig 2: View Of Arbor Press
    GM256104Courtesy of GENERAL MOTORS CORP.
  8. Lower the arbor press head onto the CV joint assembly until the tripot spider is next to the spacer ring. Do not exceed 4,000 lbs (1,779 N) press load during assembly.
  9. Remove the halfshaft assembly from the arbor press.
  10. Place the new spacer ring (2) on the halfshaft bar groove at the end of the halfshaft bar.
    Fig 3: View Of Tripot Spider Assembly
    GM256120Courtesy of GENERAL MOTORS CORP.
  11. Slide the tripot seal (7) to the corresponding groove on the halfshaft bar.
    Fig 4: Crimping The Small Seal Retaining Clamp
    GM256109Courtesy of GENERAL MOTORS CORP.
  12. Crimp the small seal retaining clamp (6) using J 35910  , a torque wrench (8), and a breaker bar (9).
  13. Place approximately 1/4 of the grease from the service kit in seal. Use the remainder to repack the housing.
  14. Install the new trilobal tripot bushing (2) to housing (1). Ensure the bushing (2) is flush with the face of the housing (1).
    Fig 5: Sliding The Housing Over The Spider Assembly On The Halfshaft Bar
    GM513691Courtesy of GENERAL MOTORS CORP.
  15. Slide the housing (1) over the spider assembly on the halfshaft bar (3).
    IMPORTANT: The end of the inboard seal (4) must be next to the seal stop on the trilobal tripot bushing (2).
  16. Position the large seal retaining clamp around the inboard seal (4).
  17. Engage the inboard seal (4).
    IMPORTANT: The halfshaft inboard seal (2) must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard seal (2) is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing to equalize the pressure. Shape the halfshaft inboard seal (2) properly by hand. Remove the thin, flat, blunt tool.
  18. Position joint assembly at the proper vehicle dimension.
    • For vehicles with 2.2L engines and automatic transmissions, dimension a=90 mm (3.5 in).
    • For all other vehicles, dimension a=115 mm (4.5 in).
      • Fig 6: Identifying Axle Shaft/CV Joint Assembly Compontents And Installed Boot Measurement Dimension
      GM221916Courtesy of GENERAL MOTORS CORP.
  19. Align the following items while latching:
    • The halfshaft inboard seal (3)
    • The housing (1)
    • The large clamp (2)
    Fig 7: Crimping Large Clamp
    GM513699Courtesy of GENERAL MOTORS CORP.
  20. Latch the seal retaining clamp (2) using J 35566  if the clamp is earless or crimp the seal retaining clamp (2) using J 35910  if the joint uses an eared clamp.
  21. Stroke the joint to full extension and compression several times to distribute the grease.
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