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Inner Joint & Seal (For 2004 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. Place the new small swage ring onto the small end of the joint seal. See Figure . Slide the joint seal and the small swage ring onto the half-shaft bar. Position the small end of the joint seal into the joint seal groove on the half-shaft bar.
  2. Mount drive axle swage ring clamp in a vise and proceed as follows:
    1. Position the inboard end of the half-shaft assembly in tool drive axle swage ring clamp.
    2. Align the top of seal neck on the bottom die using the indicator.
    3. Place the top half of the drive axle swage ring clamp on the lower half.
    4. Before proceeding, ensure there are no pinch points on the half-shaft inboard seal. This could cause damage to the half-shaft inboard seal.
    5. Insert bolts.
    6. Tighten bolts by hand until snug.
  3. Align the half-shaft inboard seal, the half-shaft bar and the swage ring. Tighten each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
  4. Install the spacer ring into the groove of the half-shaft bar using snap ring pliers.
  5. Slide the tripot joint spider assembly toward the spacer ring as far as it will go on the half-shaft bar. Install the spacer ring into the groove of the half-shaft bar snap ring pliers. Place approximately half of the grease from the service kit in the half-shaft inboard seal. Use the remainder of the grease to repack the housing.
  6. Install the new trilobal tripot bushing to housing. Position the larger new seal retaining clamp on the half-shaft inboard seal. Slide the housing over the tripot joint spider assembly on the half-shaft bar.
  7. Slide the large diameter of the half-shaft 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.
    8. NOTE: The half-shaft inboard seal must not be dimpled, stretched out or out of shape in any way. If the half-shaft 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 in order to equalize the pressure. Shape the half-shaft inboard seal properly by hand. Remove the tool.
  8. Position the joint assembly at the proper vehicle dimension.
    • On vehicles with 4.0L and 3.8L supercharged engines, dimension is 4.37" (111 mm).
    • On vehicles with 3.8L engine, dimension is 3.75" (95 mm).
  9. Align the half-shaft inboard seal, the tripot housing and the large seal retaining clamp while latching. Crimp the seal retaining clamp with drive axle seal clamp pliers to specifications. See TORQUE SPECIFICATIONS  . Add the breaker bar and the torque wrench to drive axle seal clamp pliers, if necessary.
  10. Inspect the gap dimension "A" on the clamp ear. See Figure . If gap dimension is larger than shown, continue tightening until gap dimension of 0.102" (2.60 mm) is reached. Fully stroke the joint several times to disperse the grease.
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