Assembly Procedure

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. 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 inboard seal (1). Do not swage.
Slide the halfshaft inboard seal (1) onto the halfshaft bar.
Position the neck of the halfshaft inboard seal (1) in the seal groove (3) on the halfshaft bar.

Fig 1: Installing Swage Ring & Halfshaft Inboard Seal
Courtesy of GENERAL MOTORS CORP.
Position the inboard end of the halfshaft assembly (1) using J 41048 .

Fig 2: Positioning Inboard End Of Halfshaft Assembly Using J 41048
Courtesy of GENERAL MOTORS CORP.
Align the swage ring (2) by performing the following steps:
NOTE: Before proceeding, ensure there are no pinch points on the inboard seal (1). This could cause damage to the inboard seal (1).
1. 5.1. Place the top half of J 41048 on the lower half of J 41048 .
2. 5.2. Insert the bolts.
3. 5.3. Tighten the bolts by hand until snug.
  
  Fig 3: Aligning Swage Ring
  Courtesy of GENERAL MOTORS CORP.
  
  NOTE: Refer to FASTENER NOTICE .
  
  IMPORTANT: Align the following items:
  - The inboard seal (1)
  - The housing
  - The swage ring (2)
  Tighten
  
  Each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
4. 5.4. Loosen the bolts.
5. 5.5. Separate the dies.
6. 5.6. Check the swage ring (2) for any "lip" deformities. If present, place the ring (2) back into the J 41048 ensuring the swage ring (2) covers the whole swaging area.
7. 5.7. Re-swage the swage ring (2).
Install the spacer ring (3) on the halfshaft bar (4) and beyond the second groove.
IMPORTANT: Ensure that the counterbored face of the tripot joint spider (2) faces the end of the halfshaft bar (4).
Slide the tripot joint spider assembly (2) toward the spacer ring (3) as far as it will go on the halfshaft bar (4).
Install the halfshaft bar retaining ring (1) in the groove of the halfshaft bar (4) using J 8059 .
Slide the tripot joint spider assembly (2) towards the end of the halfshaft bar (4).
Reseat the spacer ring (1) in the groove on the halfshaft bar (4).
Place approximately half of the grease from the service kit in the inboard seal. Use the remainder of the grease to repack the housing.

Fig 4: Identifying Tripot Joint Spider Assembly
Courtesy of GENERAL MOTORS CORP.
Install the trilobal tripot bushing to housing. Ensure the trilobal tripot bushing is flush with the face of the housing.
Position the larger new clamp on the inboard seal.
Slide the housing over the tripot joint spider assembly on the halfshaft bar.
Slide the large diameter of the inboard seal, with the larger clamp in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
IMPORTANT: The inboard seal (2) must not be dimpled, stretched out or out of shape in any way. If the inboard seal (2) is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing to equalize the pressure. Shape the inboard seal properly by hand. Remove the tool.
Position the joint assembly at the proper vehicle dimension.

Fig 5: Identifying Inboard Seal
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
Align the following items while latching:
- The inboard seal
- The housing (2)
- The large seal retaining clamp (3)
Crimp the seal retaining clamp (3) with J 35910 .
Tighten

Crimp the clamp (3) to 174 N.m (130 lb ft).
Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.

Fig 6: Crimping Seal Retaining Clamp
Courtesy of GENERAL MOTORS CORP.