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.

Install the new seal retaining clamp (2) on the neck of the seal. Do not crimp.
Slide the seal (1) onto the halfshaft bar and position the neck of the seal in the seal groove (3) on the bar.

Fig 1: Installing Seal Clamp On Neck Of Seal
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Crimp the seal retaining clamp (1) using the J 35910 , a breaker bar, and a torque wrench.

Fig 2: View Of CV Joint Seal Retaining Clamp
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the seal retaining clamp to 136 N.m (100 lb ft).
Check the gap dimension, continue tightening until the gap dimension is reached.
Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race.

Fig 3: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage

Courtesy of GENERAL MOTORS CORP.

Hold the inner race 90 degrees to centerline of cage (4) with the lands of the inner race (2) aligned with the windows (3) of the cage.
Insert the inner race into the cage.
IMPORTANT: Ensure that the retaining ring side of the inner race faces the halfshaft bar.
Place the cage and the inner race into the outer race.
Insert the first chrome ball then tilt the cage in the opposite direction in order to insert the opposing ball.
Repeat this process until all 6 balls are in place.
Place approximately half the grease from the service kit inside the seal and pack the CV joint with the remaining grease.
Push the CV joint (2) onto the bar (1) until the retaining ring is seated in the groove on the bar.

Fig 4: Pushing The CV Joint Onto The Bar Until The Retaining Ring Is Seated In The Groove On The Bar
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Ensure that the seal (1) is not dimpled, stretched, or out of shape. If the seal is not shaped correctly, equalize the pressure in the seal and shape the seal properly by hand.
Slide large diameter of the seal (1) with the (2) in place over the outside of the CV joint outer race (3).

Fig 5: View Of Boot And Large Seal Retaining Clamp
Courtesy of GENERAL MOTORS CORP.
Locate the seal lip in the groove on the CV joint outer race (3).
Crimp the seal retaining clamp (1) using the J 35910 , a breaker bar (3), and a torque wrench (2).
Tighten: Tighten the seal retaining clamp to 176 N.m (130 lb ft).

Fig 6: Crimping Seal Retaining Clamp
Courtesy of GENERAL MOTORS CORP.
Check the gap dimension, continue tightening until the gap dimension is reached (dimension a=1.90mm (1/16 in).