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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 848 (Wheel Drive Shafts) >> Repair Instructions >> Wheel Drive Shaft Inner Joint and Seal Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive 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 wheel drive shaft.
    Fig 1: Removing/Installing Axle Shaft Boot Seal
    GM174617Courtesy of GENERAL MOTORS CORP.
  1. Wrap a shop towel around the axle shaft.
  2. Place the wheel drive shaft horizontally in a bench vise.
  3. Install a new small seal retaining clamp onto the wheel drive shaft.
  4. Install the seal onto the axle shaft.
    5. Fig 2: Cage To Axle Shaft
    GM174652Courtesy of GENERAL MOTORS CORP.
  5. Install the cage onto the axle shaft so the smaller diameter end faces the vise.
    6. IMPORTANT: The inner race spline relief must face away from the end of the axle shaft.
    Fig 3: Installing Inner Race To Axle Shaft
    GM174653Courtesy of GENERAL MOTORS CORP.
  6. Install the inner race onto the axle shaft.
    1. Engage the inner race splines onto the axle shaft splines.

      Be sure to install the inner race spline relief side onto the axle shaft first.

    2. Position a wood block squarely over the end of the inner race.
    3. Use a hammer to begin to drive the inner race onto the axle shaft.
    4. Reposition the wood block along the face of the inner race to avoid the axle shaft.
    5. Work evenly around the inner race and continue to drive the inner race, until you feel the inner race seat fully onto the axle shaft.
    6. Inspect to be sure that the axle shaft snap ring groove is exposed.
    7. Fig 4: Removing/Installing Axle Shaft Snap Ring
    GM174648Courtesy of GENERAL MOTORS CORP.
  7. Install the snap ring to the axle shaft.
  8. Position the cage so the cage lands align with the inner race ball tracks.
  9. Install the cage onto the inner race.
  10. Position the cage windows to align with the inner race ball tracks.
    11. Fig 5: Inserting Grease From The Service Kit Into The Outer Race
    GM174656Courtesy of GENERAL MOTORS CORP.
  11. Insert approximately 60 percent of the grease from the service kit into the outer race.
  12. Position the wheel drive shaft vertically in the bench vise so the inner joint end is up.
  13. Apply a small amount of the grease from the service kit to the cage windows and inner race ball tracks.
    Fig 6: Applying Grease From The Service Kit To The Cage Windows And Inner Race Ball Tracks
    GM174654Courtesy of GENERAL MOTORS CORP.
  14. Insert the remaining grease from the service kit into the seal.
    15. Fig 7: View Of Balls, Cage & Inner Race
    GM174646Courtesy of GENERAL MOTORS CORP.
  15. Install the outer race retaining ring onto the axle shaft.

    Position the retaining ring below the cage toward the vise.

  16. Install the balls through the cage windows to the inner race ball tracks.

    Use the seal to keep the balls in position if necessary.

    17. Fig 8: View Of Outer Race At Axle Shaft
    GM174641Courtesy of GENERAL MOTORS CORP.
  17. Install the outer race onto the axle shaft.
    1. Be careful not to allow the grease in the outer race to leak out.
    2. Align the outer race ball tracks to the balls.
    3. Slide the outer race down over the balls.
  18. Position the wheel drive shaft horizontally in the bench vise.
  19. Engage the outer race retaining ring.
    1. Slide the outer race toward the vise.
    2. Insert the outer race retaining ring into the groove along the outer edge of the outer race.
    3. Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track).
  20. Position the large diameter end of the seal onto the outer race.
    21. Fig 9: Positioning Small Seal Retaining Clamp To Neck Of Seal
    GM174629Courtesy of GENERAL MOTORS CORP.
  21. Position the small seal retaining clamp (3) onto the neck of the seal (4).
  22. Position the seal and small retaining clamp to the axle shaft (2) as shown.
  23. Measure the distance (1) between the edge of the seal and the edge of the last axle shaft groove closing edge; adjust fit accordingly.

    Specification:  2.5 mm (0.10 in)

    24. Fig 10: Crimping Small Seal Retaining Clamp
    GM174657Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The seal retaining clamp must not be over-tightened or under-tightened.
  24. Crimp the small seal retaining clamp using the J 42572  . See Special Tools and Equipment .

    Tighten:  Tighten the small seal retaining clamp until the base of the omega (Ω) shape has a gap width (1) between 2 and 3 mm (0.079 and 0.118 in), with a difference in the gap width from side to side no greater than 0.4 mm (0.016 in). The clamping hold time must be no less than 2 seconds.

    25. Fig 11: Measuring The Distance Between The End Of The Seal And The End Of The Joint Outer Race
    GM174664Courtesy of GENERAL MOTORS CORP.
  25. Measure the distance (1) between the end of the seal and the end of the joint outer race; adjust the plunging motion of the joint accordingly.

    Specification:  224-228 mm (8.82-8.98 in)

  26. Position the large seal retaining clamp (2) onto the seal (3).
  27. Position the seal and large retaining clamp to the joint outer race (4) as shown.
    Fig 12: Positioning The Seal And Large Retaining Clamp To The Joint Outer Race
    GM174635Courtesy of GENERAL MOTORS CORP.
  28. Measure the distance (1) between the edge of the seal and the edge of the joint outer race last groove closing edge; adjust fit accordingly.

    Specification:  0.8 mm (0.03 in)

    29. IMPORTANT: The seal must not be dimpled, stretched or out of shape in any way.
  29. Inspect the seal for proper shape.

    If the seal is NOT shaped correctly, equalize the pressure in the seal and shape the seal properly by hand.

  30. Inspect the seal for damage.

    If the seal has been cut or punctured during assembly, you must discard and replace the seal.

  31. Align the following items while latching:
    • The wheel drive shaft inboard seal (2)
    • The tripot housing
    • The large seal retaining clamp (3)
  32. Using the J 46588  , latch the large seal retaining clamp. See Special Tools and Equipment . Ensure that the latching tangs are fully engaged in the large seal clamp band.
    Fig 13: Latching The Large Seal Retaining Clamp Using J 46588
    GM1034498Courtesy of GENERAL MOTORS CORP.
  33. Remove the wheel drive shaft from the bench vise.
  34. Distribute the grease within the inner CV joint.

    Plunge the joint back and forth four or five times.

  35. Inspect the inner CV joint and wheel drive shaft for smooth operation.
    1. Hold the wheel drive shaft vertically, with the outer joint at the bottom.
    2. Rotate the wheel drive shaft four or five times in a circular motion.

To install the wheel drive shaft into the vehicle, refer to Wheel Drive Shaft Replacement .

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