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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 27 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.
  1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp.
  2. Remove the small seal retaining clamp from the halfshaft bar (4) with a side cutter. Discard the seal retaining clamp.
  3. Separate the seal (5) from the CV joint outer race (1) at large diameter and slide the seal (5) away from joint along bar (4).
    Fig 1: Removong Race Retaining Ring
    GM221901Courtesy of GENERAL MOTORS CORP.
  4. Wipe the grease from the face of the CV joint inner race (2).
  5. Spread the ears on the race retaining ring (3) using the J 8059   and remove the CV joint assembly (1) from the bar (4).
  6. Remove the seal (5) from the bar (4).
  7. Use a brass drift and a hammer in order to gently tap on the CV joint cage (1) until the cage is tilted enough to remove the first chrome alloy ball (2).
    Fig 2: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage
    GM211933Courtesy of GENERAL MOTORS CORP.
  8. Tilt the cage in the opposite direction in order to remove the opposing ball.
  9. Repeat this process until all 6 balls are removed.
  10. Position the CV joint cage (4) and the CV joint inner race 90 degrees to the centerline of the CV joint outer race (1).

    Align the CV joint cage windows (3) with the lands of the CV joint outer race (2).

    Fig 3: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
  11. Remove the CV joint cage (4) and the CV joint inner race from the CV joint outer race (1).
  12. Rotate the CV joint inner race 90 degrees to the centerline of the CV joint cage with the lands of the CV joint inner race (1) aligned with the windows of the CV joint cage (2).
    Fig 4: View Of Inner Race & Cage
    GM214947Courtesy of GENERAL MOTORS CORP.
  13. Pivot the inner race into the cage window and remove the inner race.
  14. Clean the inner and outer race assemblies, the CV joint cage and the balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
  15. Dry all of the parts.
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