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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> Drivelines & Axles >> Axle Shafts - Front >> Overhaul >> Axle Shaft Outer Joint & Seal >> Reassembly

Axle Shaft Outer Joint & Seal: Reassembly

  1. Inspect all of the parts for unusual wear, cracks, or other damage. Put a light coat of the recommended grease on the inner and the outer race grooves. Insert the inner race into the cage by rotating the inner race downward. Hold the inner race at 90 degrees to the centerline of the cage.
  2. Align the lands of the inner race with the windows of the cage. Rotate the inner race downward to insert the inner race into the cage. Insert the cage and inner race into the outer race. Place a brass drift against the cage. Tap gently on the brass drift in order to tilt the cage. Install the first ball when the cage tilts. Repeat previous step to reinstall all of the balls.
  3. Pack the CV joint seal 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. Place the new small swage clamp onto the CV joint seal. See .Figure Place the large retaining clamp on the seal. Position the small end of the CV joint seal into the joint seal groove on the halfshaft bar.
  4. Position the outboard end of the halfshaft assembly in Swage Clamp Tool. Align the swage clamp within Swage Clamp Tool. Place the top half of the Swage Clamp Tool on the bottom half. Check to make sure there are no pinch points on the seal before proceeding with procedures. Insert the bolts. Tighten the bolts by hand until snug.
  5. Align the seal, the halfshaft bar and the swage clamp. Tighten each bolt 180 degrees at a time, using a ratchet wrench. Alternate between each bolt until both sides are bottomed. Loosen the bolts. Separate the dies. Check the swage clamp for any "lip" deformities. If the deformities exist, place the swage clamp back into the Swage Clamp Tool.
  6. Place the retaining snap ring into the CV joint inner race. The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint is in the proper position. Slide the CV joint onto the halfshaft bar. Pull on the CV joint to verify engagement.
  7. Slide the large diameter of the CV joint seal, with the large retaining ring in place, over the outside edge of the CV joint outer race. Position the lip of the CV joint seal into the groove on the CV joint outer race. Manipulate the CV joint seal to remove any excess air.
  8. Secure the large retaining clamp to the housing with Drive Axle Seal Clamp Pliers (or equivalent), a breaker bar, and a torque wrench. Torque the large retaining clamp to specifications. See TORQUE SPECIFICATIONS . Check the gap dimension on the clamp ear. Gap dimension is .085" (2.15 mm).
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