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Axle Shaft Outer Joint & Boot: Reassembly

WARNING: This page is about a different car, the 2003 Chevrolet Corvette and 2002 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Axle shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the axle 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 axle shaft.
  1. Position the cage so the larger radius corners of the cage windows are up.
  2. Position the inner race 90 degrees to the centerline of the cage.
  3. Begin to insert the inner race up through the bottom of the cage. See Figure .
  4. Align a land of the inner race to a window of the cage.
  5. Insert the inner race land into the cage window.
  6. Rotate the remainder of the inner race into the cage.
  7. Rotate the inner race within the cage so that the grooved surface of the inner race is facing up.
  8. Align the inner race ball tracks with the cage windows.
  9. Wrap a shop towel around the joint outer race splined shaft.
  10. Place the outer race vertically in a bench vise.
  11. Position the cage and inner race 90 degrees to the centerline of the outer race.
  12. Align 2 cage windows at 0 and 180 degrees. Rotate the inner race and cage assembly in the vertical plane.
  13. Align the 2 windows at 0 and 180 degrees with 2 of the outer race lands.
  14. Insert the cage and inner race into the outer race.
    NOTE: The larger radius corners of the cage windows should be positioned up and the grooved surface of the inner race should be visible.
  15. Position the cage and inner race so they are level.
  16. Align the cage windows and inner race ball tracks with the outer race ball tracks. Rotate the appropriate component(s).
  17. Position a cage window and inner race ball track for ball installation.
    1. Press down on the cage following one of the outer race ball tracks. The opposing cage window and inner race ball track will be accessible for ball installation.
    2. After you install the first ball, you will need to use a brass drift and a hammer to tap gently on the cage, in order to drive the cage and inner race down completely.
    NOTE: No gap should exist between the ball and the inner race ball track.
  18. Insert a ball through the cage window onto the inner race ball track. Tap the ball lightly with a plastic tipped hammer.
  19. Position the cage and inner race so they are level.
    NOTE: The ball installation sequence must be followed as shown. See Figure .
  20. Repeat steps  17 - 19 in the installation sequence until you install all 6 balls.
  21. 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.
  22. Remove the outer joint from the bench vise.
  23. Wrap a shop towel around the axle shaft.
  24. Place the axle shaft horizontally in a bench vise.
  25. Install a NEW small seal retaining clamp onto the axle shaft.
  26. Install the boot onto the axle shaft.
  27. Install the axle shaft retaining ring to the axle shaft.
  28. Position the outer joint horizontally.
  29. Engage the inner race splines onto the axle shaft splines.
  30. Compress the axle shaft retaining ring.
    1. Press one end of the retaining ring, using a flat bladed screwdriver or equivalent tool, into the axle shaft groove while firmly pressing the outer joint onto the axle shaft.
    2. Continue to work around the retaining ring until it is compressed.
    NOTE: The axle shaft and inner race must be fully seated to each other.
  31. Install the outer joint to the axle shaft.
    1. Position a wood block squarely over the end of the outer joint threaded shaft.
    2. Use a hammer to drive the outer joint onto the shaft.
    3. Continue to drive the outer joint until you feel the outer joint seat fully onto the axle shaft.
    4. Inspect to be sure that the axle shaft and the inner race stepped surfaces are fully seated to each other.
  32. Insert the remaining grease from the service kit into the boot.
  33. Position the small seal retaining clamp onto the neck of the boot. See Figure . Position the boot and small retaining clamp to the axle shaft.
  34. Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge. Adjust to fit accordingly. See AXLE SHAFT SPECIFICATIONS  .
    NOTE: The seal retaining clamp must not be over-tightened or under-tightened.
  35. Crimp the small seal retaining clamp using the axle shaft seal clamp pliers. See Figure . Tighten the small seal retaining clamp to specification. See AXLE SHAFT SPECIFICATIONS  . The clamping hold time must be no less than 2 seconds.
  36. Position the large seal retaining clamp onto the boot.
  37. Position the seal and large retaining clamp to the joint outer race. See Figure .
  38. Measure the distance of the edge of seal-to-edge of joint outer race last groove. Adjust to specification. See AXLE SHAFT SPECIFICATIONS  .
    NOTE: The boot must not be dimpled, stretched or out of shape in any way.
  39. Inspect the boot for proper shape. If the boot is not shaped correctly, equalize the pressure in the boot and shape the boot properly by hand.
  40. Inspect the boot for damage. If the boot has been cut or punctured during assembly, you must discard and replace the boot.
  41. Align the following items while latching:
    • The axle shaft outer boot.
    • The outer housing
    • The large seal retaining clamp.
  42. Using the axle seal crimp pliers, latch the large seal retaining clamp. See Figure . Ensure that the latching tangs are fully engaged in the large seal clamp band.
  43. Rotate the housing 4 or 5 times in order to distribute the grease throughout the ball bearings.
  44. Inspect the outer CV joint and axle shaft for smooth operation. This will also distribute the grease within the joint.
    1. Hold the axle shaft vertically, with the outer joint at the bottom.
    2. Rotate the axle shaft 4 or 5 times in a circular motion.
    To install the axle shaft into the vehicle, see AXLE SHAFTS  under REMOVAL & INSTALLATION.
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