LEMON Manuals: Even more car manuals for everyone
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) >> Disassembly Procedure

Disassembly 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.
IMPORTANT: Due to the helical splines on the halfshaft 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.
  2. Remove the small seal retaining clamp from the halfshaft bar with a side cutter and discard.
  3. Separate the CV joint seal from the CV joint race (2) at the large diameter.
  4. Slide the seal away from the joint along the halfshaft bar.
  5. Wipe the grease from the face of the CV joint inner race (1).
  6. Before removing the CV joint assembly from the half shaft bar, perform the following procedure:
    1. Choose a reference mark (B) on the halfshaft bar.
    2. Measure the distance between the reference mark (B) and the face of the CV joint inner race (1). Make a note of this measurement. The measurement is (A).
    3. Mark the inboard side (toward the center of the half shaft bar) of the CV joint inner race (1) as a reference.
    4. Inspect the CV joint inner race/halfshaft bar interface for the presence of a retaining ring. If present, remove the retaining ring using J 8039-A  .
    Fig 1: Placing Reference Mark (B) On The Halfshaft Bar
    GM256095Courtesy of GENERAL MOTORS CORP.
  7. Clamp the halfshaft (1) into a vise.
    Fig 2: Clamping The Halfshaft Into A Vise
    GM256097Courtesy of GENERAL MOTORS CORP.
  8. Attach the J 41398  to the threaded area of the outer race (2).
    Fig 3: View Of CV Puller
    GM256100Courtesy of GENERAL MOTORS CORP.
  9. Attach J 2619-01  onto the outer end of the J 41398  .
    Fig 4: Attaching Slide Hammer Onto The Outer End Of The J 41398
    GM256103Courtesy of GENERAL MOTORS CORP.
  10. Use the J 2619-01  to remove the CV joint from the halfshaft bar.
  11. Remove J 2619-01  and J 41398  from the CV joint.
    IMPORTANT: Never reuse the retaining ring.
  12. Remove the retaining ring from the halfshaft bar. Discard the retaining ring.
  13. Remove the CV joint seal (1) from the halfshaft bar.
  14. Place a brass drift against the CV joint cage (1).
    Fig 5: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage
    GM211933Courtesy of GENERAL MOTORS CORP.
  15. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
  16. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts.
  17. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
  18. Repeat this process to remove all six of the balls.
  19. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows with the lands of the outer race (2).
    Fig 6: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
  20. Lift out the cage (4) and the inner race.
  21. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
    Fig 7: View Of Inner Race & Cage
    GM214947Courtesy of GENERAL MOTORS CORP.
  22. 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.
  23. Dry all the parts.
  24. Check the CV joint assembly for unusual wear, cracks, or other damage.
  25. Replace any damaged parts.
  26. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
scientia non olet · About LEMON Manuals