Assembly Procedure

WARNING: This page is about a different car, the 2004 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

IMPORTANT: Before installing the boots, wrap the spline of the outboard joint with vinyl tape to prevent possible tearing of the boots.

Temporarily install new outboard and inboard boots with new clamps on the outboard joint shaft.

Fig 1: Installing Cage To The Outboard Joint Shaft

GM824915

Courtesy of GENERAL MOTORS CORP.

Install the cage to the outboard joint shaft.

Fig 2: Installing Inner Race

GM824917

Courtesy of GENERAL MOTORS CORP.

Using a brass bar and hammer, install the inner race on the outboard joint shaft.

Fig 3: Aligning Inboard Joint Shaft And Outboard Joint Shaft

GM824923

Courtesy of GENERAL MOTORS CORP.

Install a new snap ring.
Align the inboard joint shaft and outboard joint shaft.

Fig 4: Grease Capacity Of Outboard Joint

GM824921

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: The grease capacity of the outboard joint is approximately 71-81g (2.5-2.9 oz) which is yellow in color. The inboard joint grease capacity is approximately 132-142g (4.7-5.0 oz) which is gray in color.

Insert approximately 60 percent of the grease from the service kit into the outer joint.
1. Spread the grease onto the ball tracks, the balls, the cage and the inner race.
2. Spread the remainder of the grease into the bottom of the outer race.
3. Insert the remaining grease from the service kit into the boot.

Fig 5: View Of Axle Shaft Retaining Ring

GM174601

Courtesy of GENERAL MOTORS CORP.

Install a new retaining ring to the axle shaft.
Install the boots into the shaft grooves.

Fig 6: Drive Shaft At Standard Length

GM824925

Courtesy of GENERAL MOTORS CORP.

Ensure that the drive shaft is at standard length.
Specification: The standard length is approximately 688.33-698.33 mm (27.098-27.492 in).
Position the small boot retaining clamp onto the neck of the boot.
Position the small boot and small retaining clamp to the axle shaft.

Fig 7: Using J 42572 To Crimp Seal Retaining Clamp

GM174632

Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Using the J 42572 , crimp the small boot retaining clamp. See Special Tools and Equipment .
Position the large boot retaining clamp onto the boot.
Position the boot and large retaining clamp to the joint outer race.

IMPORTANT: The boot must not be dimpled, stretched or out of shape in any way.

Inspect the boot for proper shape.
If the boot is NOT shaped correctly, equalize the pressure in the boot by lifting the boot edge slightly and shape the boot properly by hand.
Inspect the boot for damage.
If the boot has been cut or punctured during assembly, you must discard and replace the boot.

IMPORTANT: The boot retaining clamp must not be over tightened or under-tightened.

Using the J 42572 , crimp the large boot retaining clamp. See Special Tools and Equipment .
Inspect the outer CV joint and wheel drive shaft for smooth operation. This will also distribute the grease within the joint.
1. Hold the wheel drive shaft vertically, with the outer joint at the bottom.
2. Rotate the wheel drive shaft 4 or 5 times in a circular motion.