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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 Outer Joint and Seal Replacement (Drive Shaft Bar Diameter 24 MM) >> 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. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race.
  2. Hold the inner race 90 degrees to the centerline of the cage with the lands of the inner race (1) aligned with the windows of cage (2).
    3. Fig 1: View Of Inner Race & Cage
    GM214947Courtesy of GENERAL MOTORS CORP.
  3. Insert the inner race into the cage.
  4. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows (3) with the lands of the outer race (2).
    Fig 2: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the inner race is oriented the same as prior to disassembly. Use the reference mark placed earlier.
  5. Install the cage and the inner race into outer race.
  6. Place a brass drift against the CV joint cage (1).
    Fig 3: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage
    GM211933Courtesy of GENERAL MOTORS CORP.
  7. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
  8. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts.
  9. Repeat this process to install all six of the balls.
  10. Pack the CV joint with half of the grease supplied in the service kit.
  11. Install the new small retaining clamp (2) on the neck of the seal (3). Do not crimp.
    Fig 4: Installing The New Small Retaining Clamp
    GM621765Courtesy of GENERAL MOTORS CORP.
  12. Clean the halfshaft bar (1). Use a wire brush to remove any rust in the seal mounting area (grooves).
  13. Slide the CV joint seal (3) onto the halfshaft bar (1). Expose the reference mark (4) by sliding the CV joint seal (3) up the halfshaft bar (1) toward the tripot end.
  14. Position the large seal retaining clamp around the joint seal.
  15. Place the new retaining ring onto the halfshaft bar.
  16. While supporting the tripot assembly, place the halfshaft assembly onto the arbor press with the CV assembly under the press head.
    Fig 5: View Of Arbor Press
    GM256104Courtesy of GENERAL MOTORS CORP.
  17. 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 1779 N (4,000 lbs) press load during assembly.
  18. Remove the halfshaft assembly from the arbor press.
  19. Measure the distance between the reference mark on the halfshaft bar (B) and the face of the CV joint inner race (1).
    Fig 6: Measuring The Distance Between The Reference Mark On The Halfshaft Bar And The Face Of The CV Joint Inner Race
    GM256095Courtesy of GENERAL MOTORS CORP.
  20. Compare the mark with the measurement made before disassembly.
  21. Repeat the previous four steps if the current measurement does not match the measurement made before disassembly.
  22. Place the neck of the CV joint seal into the seal groove on the halfshaft bar.
    IMPORTANT: Check the clamp position during the crimping operation in order to ensure the clamp (1) is positioned correctly around the entire circumference.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  23. Crimp the small retaining clamp (1) by using J 35910  , a breaker bar, and a torque wrench.
    Fig 7: View Of CV Joint Seal Retaining Clamp
    GM214026Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the seal retaining clamp to 136 N.m (100 lb ft).

  24. Check the gap dimension. Continue tightening until the gap dimension is reached.
  25. Place the remaining grease from the service kit inside the seal.
  26. Measure approximately 17.5 mm (11/16 in) up from the bottom edge of the CV outer joint assembly.
    Fig 8: Measuring CV Outer Joint Assembly
    GM256106Courtesy of GENERAL MOTORS CORP.
  27. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of CV joint.
    IMPORTANT: 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.
  28. Locate the seal lip to the ridge of the CV outer joint assembly as measured in the previous step.
  29. Crimp seal retaining clamp (1) with J 35910  , a breaker bar (3), and a torque wrench (2).

    Tighten:  Tighten seal retaining clamp to 176 N.m (130 lb ft).

    Fig 9: Crimping Seal Retaining Clamp
    GM245263Courtesy of GENERAL MOTORS CORP.
  30. Check the gap dimension. Continue tightening until the correct gap dimension is reached. Dimension a=3.9 mm (0.15 in).
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