Assembly Procedure

WARNING: This page is about a different car, the 2002 Pontiac Montana, 2002 Oldsmobile Silhouette, and 2002 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.

Install the new swage ring (2) on the neck of the outboard seal (1). Do not swage.
Slide the outboard seal (1) onto the halfshaft bar and position the neck of the outboard seal (1) in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove (3).

Fig 1: Installing Swage Ring & Neck Of Outboard Seal
Courtesy of GENERAL MOTORS CORP.
The swage ring is swaged using J 41048 by the following method:
1. 3.1. Position the outboard end of the halfshaft assembly (1) in J 41048 .
2. 3.2. Align the swage ring.
3. 3.3. Place the top half of J 41048 on the lower half of J 41048 .
  NOTE: Do not cut through the wheel drive 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.
  
  Fig 2: Installing Swage Ring On Halfshaft Assembly Using J 41048
  Courtesy of GENERAL MOTORS CORP.
  IMPORTANT:
  - The outboard seal (1)
  - The housing
  - The swage ring
  NOTE: Refer to FASTENER NOTICE .
4. 3.4. Insert the bolts (2) and tighten 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.
Loosen the bolts and separate the dies.
Check swaged ring (2) for any "lip" deformities. If present, place the ring (2) back into the J 41048 making sure the ring covers the whole swaging area. Then re-swage the ring.

Fig 3: Swaged Ring & J 41048
Courtesy of GENERAL MOTORS CORP.
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 (1) aligned with the windows of the cage (2) and insert the inner race into the cage.

Fig 4: Positioning Inner Race 90 Degrees To Centerline Of Cage
Courtesy of GENERAL MOTORS CORP.
Hold the cage and the inner race 90 degrees to centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race.
IMPORTANT: Be sure that the retaining ring side of the inner race faces the halfshaft bar.
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.
Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.

Fig 5: CV Joint Cage
Courtesy of GENERAL MOTORS CORP.
Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the halfshaft bar.

Fig 6: CV Joint & Halfshaft Bar
Courtesy of GENERAL MOTORS CORP.

IMPORTANT: The outboard seal (1) must not be dimpled, stretched or out of shape in any way. If the outboard seal (1) is not shaped correctly, equalize the pressure in the outboard seal (1) and shape the seal properly by hand.
Slide large diameter of the outboard seal (1) with the large seal retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the seal lip in the groove on the CV joint outer race.

Fig 7: Outboard Seal & Large Seal Retaining Clamp
Courtesy of GENERAL MOTORS CORP.
Crimp the seal retaining clamp (1) using J 35910 .
Tighten

Crimp the clamp (1) to 174 N.m (130 lb ft).
Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached (dimension a= 1.9 mm (5/64 in)).

Fig 8: Crimping Seal Retaining Clamp Using J 35910
Courtesy of GENERAL MOTORS CORP.