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Axle Shaft Outer Joint & Boot: Reassembly

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  1. Inspect all of the parts for unusual wear, cracks, or other damage.
    NOTE: Replace the joint assembly if necessary.
  2. Put a light coat of the recommended grease on the inner and the outer race grooves.
  3. Insert the inner race into the cage by rotating the inner race downward. See Figure .
  4. Hold the inner race at 90 degrees to the centerline of the cage.
  5. Align the lands of the inner race with the windows of the cage. See Figure .
  6. Rotate the inner race downward to insert the inner race into the cage.
  7. Insert the cage and inner race into the outer race.
  8. Place a brass drift against the cage. See Figure .
  9. Tap gently on the brass drift in order to tilt the cage.
  10. Install the first ball when the cage tilts.
  11. Repeat previous step to reinstall all of the balls.
  12. Pack the CV joint boot 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 swage clamp onto the CV joint boot. See Figure .
  14. Place the large retaining clamp on the boot.
  15. Position the small end of the CV joint boot into the joint boot groove on the axle shaft bar.
  16. Position the outboard end of the axle shaft assembly in swage clamp tool. See Figure .
  17. Align the swage clamp within swage clamp tool. See Figure .
  18. Place the top half of the swage clamp tool on the bottom half. See Figure .
  19. Check to make sure there are no pinch points on the boot before proceeding with procedures.
  20. Insert the bolts. Tighten the bolts by hand until snug.
  21. Align the boot, the axle shaft 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.
  22. Loosen the bolts.
  23. Separate the dies.
  24. Check the swage clamp for any lip deformities. If the deformities exist, place the swage clamp back into the swage clamp tool.
    25. NOTE: Ensure that the retaining ring side of the CV joint inner race faces the axle shaft bar before installation. See Fig 1 .
  25. Place the retaining snap ring into the CV joint inner race.
    26. NOTE: The retaining snap ring inside of the inner race engages in the axle shaft bar groove with a click when the CV joint is in the proper position.
  26. Slide the CV joint onto the axle shaft bar.
  27. Pull on the CV joint to verify engagement.
  28. Slide the large diameter of the CV joint boot, with the large retaining ring in place, over the outside edge of the CV joint outer race. See Fig 2 .
  29. Position the lip of the CV joint boot into the groove on the CV joint outer race.
  30. Manipulate the CV joint boot to remove any excess air.
  31. Secure the large retaining clamp to the housing with boot clamp tool (or equivalent), a breaker bar, and a torque wrench. See Fig 3 . Tighten the large retaining clamp to specification. See TORQUE SPECIFICATIONS  .
  32. Check the gap dimension on the clamp ear.
Fig 1: Installing CV Joint To Half-Shaft
G00322067Courtesy of GENERAL MOTORS CORP.
Fig 2: Installing Boot & Retaining Ring On Outer Race
G00351321Courtesy of GENERAL MOTORS CORP.
Fig 3: Securing Retaining Ring Clamp
G99J04494Courtesy of GENERAL MOTORS CORP.
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