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Outer Joint & Seal: 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 outboard seal. See Fig 1 . DO NOT swage. Slide the outboard seal onto the axle shaft bar and position the neck of the outboard seal in the seal groove on the axle shaft bar. The largest groove below the sight groove on the axle shaft bar is the seal groove. See Fig 1 .
  2. The swage ring is swaged using drive axle swage ring clamp by the following method:
    1. Position the outboard end of the axle shaft assembly in swage ring clamp.
    2. Align the swage ring.
    3. Place the top half of swage ring clamp over the lower half of the swage ring clamp.
      CAUTION: Do not cut through the axle shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.
      NOTE: Align the outboard seal, the axle shaft bar and the he swage ring during this procedure.
    4. Insert the bolts and tighten by hand until snug. Turn each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
  3. Loosen the bolts and separate the dies. Check swaged ring for any "lip" deformities. If present, place the ring back into the Clamp making sure the ring covers the whole swaging area. Then re-swage the ring.
  4. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race aligned with the windows of the cage and insert the inner race into the cage.
    NOTE: Be sure that the retaining ring side of the inner race faces the axle shaft bar.
  5. Hold the cage and the inner race 90 degrees to centerline of the outer race and align the cage windows with the lands of the outer race. See Figure . Place the cage and the inner race into the outer race. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball. Repeat this process until all 6 balls are in place.
  6. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.
  7. Push the CV joint onto the axle shaft bar until the retaining ring is seated in the groove on the axle shaft bar.
    NOTE: The outboard seal must not be dimpled, stretched or out of shape in any way. If the outboard seal is not shaped correctly, equalize the pressure in the outboard seal and shape the seal properly by hand.
  8. Slide large diameter of the outboard seal with the large seal retaining clamp in place over the outside of the CV joint outer race and locate the seal lip in the groove on the CV joint outer race.
  9. Crimp the seal retaining clamp using drive axle seal clamp pliers. Crimp the clamp to specification. See TORQUE SPECIFICATIONS  .
  10. Check the gap dimension "A" on the clamp ear. See Figure . Continue tightening until maximum air gap dimension is 5/64" (1.9 mm).
Fig 1: Installing New Seal
G00307733Courtesy of GENERAL MOTORS CORP.
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