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Home >> Chevrolet >> 2002 >> Astro Van Passenger, AWD >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Axle Shafts >> Wheel Drive Shafts >> Repair Instructions >> Wheel Drive Shaft Outer Joint & Seal Replacement >> Assembly Procedure

Assembly Procedure

  1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary.
  2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves.
    Fig 1: CV Joint Components
    G02501880Courtesy of GENERAL MOTORS CORP.
  3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2).
  4. Align the lands of the inner race (1) with the windows of the cage (2).
  5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward.
  6. Insert the cage (4) and inner race into the outer race (1).
  7. Place a brass drift against the CV joint cage (1).
  8. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
  9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts.
  10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2).
  11. Repeat this process in order to install all six of the balls.
  12. Pack the CV joint seal (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
  13. Place the new small seal clamp (2) onto the CV joint seal.
  14. Slide the CV joint seal (1) onto the halfshaft bar.
  15. Position the small end of the CV joint seal into the joint seal groove (3) on the halfshaft bar.
  16. Secure the small seal clamp (1) using J 35910  (or equivalent), a breaker bar, and a torque wrench. Torque the small clamp (1) to 136 N.m (100 lb ft). Check the gap dimension on the clamp ear.
  17. Using your hand, pinch the new swage ring (1) into an oval shape.
  18. Slide the distorted swage ring (1) over the large diameter of the CV joint seal.

    Important:  Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (1) before installation.

  19. Slide the CV joint (2) onto the halfshaft bar (1). The retaining snap ring that is inside of the inner race engages in the halfshaft bar groove with a click when the CV joint is in the proper position.
  20. Slide the large diameter of the CV joint seal (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (3).
  21. Mount J 36652  .
  22. Pull on the CV joint (1) to verify engagement.

    Important:  Align the following items during this procedure:

    • The CV joint seal (3)
    • The housing
    • The swage ring (2)
  23. Position the CV joint end (outboard end) (1) of the halfshaft bar assembly in the bottom half of J 36652  .
  24. Install the top half of J 36652  onto the lower half of J 36652  , over the CV joint (1) and the CV joint seal.
  25. Align the swage ring and the swage ring clamp.
  26. Insert the bolts into J 36652  . Hand tighten the bolts until the bolts are snug. Each bolt 180 degrees at a time. Tighten each bolt alternately until both sides of the top half of J 36652  touch the bottom half of J 36652  .
    27. Fig 2: Drive Axle Clamp Swage Tool
    G02501890Courtesy of GENERAL MOTORS CORP.
  27. Loosen the bolts and remove the halfshaft assembly from J 36652  .
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