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Outer CV Joint & Seal: Reassembly

WARNING: This page is about a different car, the 2003 Pontiac Aztek, 2003 Buick Rendezvous, 2002 Pontiac Aztek, 2002 Buick Rendezvous, and 2001 Pontiac Aztek. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: axle shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the axle shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the axle shaft.
  1. Position the cage so the larger radius corners of the cage windows are up. Position the inner race 90 degrees to the centerline of the cage. Begin to insert the inner race up through the bottom of the cage.
  2. Align a land of the inner race to a window of the cage. Insert the inner race land into the cage window. Rotate the remainder of the inner race into the cage. Rotate the inner race within the cage so that the grooved surface of the inner race is facing up. Align the inner race ball tracks with the cage windows.
  3. Wrap a shop towel around the joint outer race splined shaft. Place the outer race vertically in a bench vise. Position the cage and inner race 90 degrees to the centerline of the outer race. Align 2 cage windows at 0 and 180 degrees. Rotate the inner race and cage assembly in the vertical plane. Align the 2 windows at 0 and 180 degrees with 2 of the outer race lands. Insert the cage and inner race into the outer race.
    4. NOTE: The larger radius corners of the cage windows should be positioned up and the grooved surface of the inner race should be visible.
  4. Position the cage and inner race so they are level. Align the cage windows and inner race ball tracks with the outer race ball tracks. Rotate the appropriate component(s).
  5. Position a cage window and inner race ball track for ball installation.
    1. Press down on the cage following one of the outer race ball tracks. The opposing cage window and inner race ball track will be accessible for ball installation.
    2. After installing the first ball, use a brass drift and a hammer to tap gently on the cage, in order to drive the cage and inner race down completely. No gap should exist between the ball and the inner race ball track.
  6. Insert a ball through the cage window onto the inner race ball track. Tap the ball lightly with a plastic tipped hammer. Position the cage and inner race so they are level.
  7. Repeat steps  5 and  6 until all 6 balls are installed in sequence. See Figure .
  8. Insert approximately 60 percent of the grease from the service kit into the outer joint.
    1. Spread the grease onto the ball tracks, the balls, the cage and the inner race.
    2. Spread the remainder of the grease into the bottom of the outer race.
  9. Remove the outer joint from the bench vise. Wrap a shop towel around the axle shaft. Place the axle shaft horizontally in a bench vise. Install a NEW small seal retaining clamp onto the axle shaft. Install the seal onto the axle shaft.
  10. Install a NEW retaining ring to the axle shaft. Position the outer joint horizontally. Engage the inner race splines onto the axle shaft splines.
  11. Compress the axle shaft retaining ring.
    1. Press the end of the retaining ring, using a flat bladed tool, into the axle shaft groove while firmly pressing the outer joint onto the axle shaft.
    2. Continue to work around the retaining ring until it is compressed.
    12. NOTE: The axle shaft and inner race must be fully seated to each other.
  12. Install the outer joint to the axle shaft.
    1. Position a wood block squarely over the end of the outer joint threaded shaft.
    2. Use a hammer to drive the outer joint onto the shaft.
    3. Continue to drive the outer joint until the outer joint seats fully onto the axle shaft.
    Insert the remaining grease from the service kit into the seal.
  13. Position the small seal retaining clamp onto the neck of the seal. Position the seal and small retaining clamp to the axle shaft as shown. See Fig 1 . Measure distance "a" between the edge of the seal and the edge of the last axle shaft groove closing edge; adjust fit accordingly. Distance "a" should be 0.1" (2.5 mm).
    14. NOTE: The seal retaining clamp must not be over-tightened or under-tightened.
  14. Using the Drive Shaft Seal Clamp Pliers (J-42572), crimp the small seal retaining clamp. Tighten the small seal retaining clamp to specification. See Fig 2 . See TORQUE SPECIFICATIONS  . Measure the air gap width. If air gap is greater than 0.079-0.118" (2-3 mm), crimp clamp until correct dimension is attained.
  15. Position the large seal retaining clamp onto the seal. See Fig 3 . Position the seal and large retaining clamp to the joint outer race. Measure the distance between the edge of the seal and the edge of the joint outer race last groove closing edge; adjust fit accordingly. Distance should be 0.03" (0.8 mm).
  16. Inspect the seal for proper shape. The seal must not be dimpled, stretched or otherwise deformed. If the seal is NOT shaped correctly, equalize the pressure in the seal by lifting the seal edge slightly and shape the seal properly by hand. Inspect the seal for damage. If the seal has been cut or punctured during assembly, you must discard and replace the seal.
    17. NOTE: The seal retaining clamp must not be over-tightened or under-tightened.
  17. Using the clamp pliers, crimp the large seal retaining clamp. Tighten the large seal retaining clamp to specification. See TORQUE SPECIFICATIONS  . See Fig 2 . Measure the air gap width in order to ensure it is between 0.079-0.118" (2-3 mm). Crimp clamp until correct dimension is attained.
  18. Inspect the outer CV joint and axle shaft for smooth operation. This will also distribute the grease within the joint. Hold the axle shaft vertically, with the outer joint at the bottom. Rotate the axle shaft 4 or 5 times in a circular motion.
Fig 1: Positioning Small Seal Retaining Clamp
G00298904Courtesy of GENERAL MOTORS CORP.
Fig 2: Tightening Drive Axle Outer CV Joint Seal (Boot) Clamp
G99F50174Courtesy of GENERAL MOTORS CORP.
Fig 3: Positioning Large Seal Retaining Clamp
G00298905Courtesy of GENERAL MOTORS CORP.
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