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Inner Joint & Seal (For 2003 Vehicles): Reassembly

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the NEW swage ring on the neck of the inboard seal. DO NOT swage. Slide the axle shaft inboard seal onto the axle shaft bar. Position the neck of the axle shaft inboard seal in the seal groove on the axle shaft bar.
  2. Position the inboard end of the axle shaft assembly using drive axle swage ring clamp. Align the swage ring by performing the following steps:
    1. Place the top half of drive axle swage ring clamp on the lower half of drive axle swage ring clamp.
      NOTE: Align the inboard seal, the axle shaft bar and the swage ring.
    2. Insert bolts. Tighten bolts by hand until snug. Tighten each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
    3. Loosen bolts. Separate the dies.
    4. Check the swage ring for any "lip" deformities. If present, place the ring back into the drive axle swage ring clamp ensuring the swage ring covers the whole swaging area.
    5. Re-swage the swage ring.
  3. Install the spacer ring on the axle shaft bar and beyond the second groove. Slide the tripot joint spider assembly toward the spacer ring as far as it will go on the axle shaft bar.
  4. Install the axle shaft bar retaining ring in the groove of the axle shaft bar using snap ring pliers. Slide the tripot joint spider assembly towards the end of the axle shaft bar. Reseat the spacer ring in the groove on the axle shaft bar. Place approximately half of the grease from the service kit in the inboard seal. Use the remainder of the grease to repack the housing.
  5. Install the trilobal tripot bushing to housing. Ensure the trilobal tripot bushing is flush with the face of the housing. Position the larger NEW clamp on the inboard seal. Slide the housing over the tripot joint spider assembly on the axle shaft bar. Slide the large diameter of the inboard seal, with the larger clamp in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
    NOTE: The inboard seal must not be dimpled, stretched out or out of shape in any way. If the inboard seal is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing to equalize the pressure. Shape the inboard seal properly by hand. Remove the tool.
  6. Position the joint assembly at the proper vehicle dimension 4" (105 mm). Crimp the seal retaining clamp with drive axle seal clamp pliers. Crimp the clamp to specification. See TORQUE SPECIFICATIONS  .
  7. Check the air gap dimension "A" on the clamp ear. See Fig 1 . Continue tightening until maximum air gap dimension is 3/32" (2.3 mm).
Fig 1: Tightening Front Axle Shaft Seal Clamp
G00072433Courtesy of GENERAL MOTORS CORP.
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