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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1039 (Wheel Drive Shafts) >> Repair Instructions >> Wheel Drive Shaft Outer Joint and Seal Replacement >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  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.
    3. Fig 1: Exploded View Of Wheel Drive Shaft Outer Joint
    GM404792Courtesy 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. Fig 2: View Of Inner Race & Cage
    GM214947Courtesy of GENERAL MOTORS CORP.
  6. Insert the cage (4) and inner race into the outer race (1).
    7. Fig 3: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
  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).
    Fig 4: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage
    GM211933Courtesy of GENERAL MOTORS CORP.
  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 boot (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 boot clamp (2) onto the CV joint seal (1).
  14. Slide the CV joint boot (1) onto the halfshaft bar.
  15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar.
    16. Fig 5: Positionng Small End Of Joint Seal Into Joint Seal Groove
    GM386688Courtesy of GENERAL MOTORS CORP.
  16. Secure the small boot clamp (1) using J 35910  (or equivalent), a breaker bar, and a torque wrench.

    Tighten:  Tighten the small clamp (1) to 136 N.m (100 lb ft).

  17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
    18. Fig 6: View Of CV Joint Seal Retaining Clamp
    GM214026Courtesy of GENERAL MOTORS CORP.
  18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape.
  19. Slide the distorted swage ring (2) over the large diameter of the boot (1).
    20. IMPORTANT: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation.
    Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position.
  20. Pull on the CV joint (4) to verify engagement.
  21. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4).
    22. Fig 7: CV Boot, Swage Ring, Halfshaft Bar & CV Joint
    GM404252Courtesy of GENERAL MOTORS CORP.
  22. Clamp the CV joint boot tightly to the CV joint outer race with the large swage ring, using the following procedure:
  23. Mount the base of J 36652 in a vise.
  24. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652.
    25. Fig 8: Clamping CV Joint Boot
    GM214030Courtesy of GENERAL MOTORS CORP.
  25. Align the following during this procedure:
    • The CV joint boot (3)
    • The CV joint assembly (1)
    • The swage ring (2)
  26. Install the top half of J 36652 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1).
  27. Align the swage ring (2) and the swage ring clamp.
    28. Fig 9: Align The Swage Ring And The Swage Ring Clamp
    GM404256Courtesy of GENERAL MOTORS CORP.
  28. Insert the bolts into J 36652. Hand tighten the bolts until the bolts are snug.

    Tighten:  Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of J 36652 touch the bottom half of the tool.

  29. Loosen the bolts and remove the halfshaft assembly from J 36652.
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