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Disassembly Procedure

WARNING: This page is about a different car, the 2007 Pontiac G5 Pursuit, 2007 Pontiac G5, and 2007 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Placing Reference Mark (B) On The Halfshaft Bar
    GM256095Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Due to the helical splines on the shaft, disassembly and assembly of the joints will be difficult. Follow the instructions provided.
  1. Remove the large seal retaining clamp from the CV joint with a hand grinder, taking care not to damage the housing. Discard the large seal retaining clamp.
  2. Remove the small seal retaining clamp from the shaft with a hand grinder, taking care not to damage the housing. Discard the small seal retaining clamp.
  3. Separate the CV joint seal from the CV joint race (2) at the large diameter.
  4. Slide the seal away from the joint along the shaft.
  5. Wipe the grease from the face of the CV joint inner race (1).
  6. Before removing the CV joint assembly from the half shaft bar, perform the following procedure:
    1. Choose a reference mark (B) on the shaft.
    2. Measure the distance between the reference mark (B) and the face of the CV joint inner race (1). Make a note of this measurement (A).
    3. Mark as a reference the inboard side, toward the center of the half shaft bar, of the CV joint inner race (1).
    4. Inspect the CV joint inner race/shaft interface for the presence of a retaining ring. If present, remove the retaining ring using J 8039-A  . See Special Tools .
    7. Fig 2: Clamping The Halfshaft Into A Vise
    GM256097Courtesy of GENERAL MOTORS CORP.
  7. Clamp the shaft (2) into a vise.
    8. Fig 3: View Of CV Puller
    GM256100Courtesy of GENERAL MOTORS CORP.
  8. Attach J 41398  to the threaded area of the outer race (2). See Special Tools .
    9. Fig 4: Attaching Slide Hammer Onto The Outer End Of The J 41398
    GM256103Courtesy of GENERAL MOTORS CORP.
  9. Attach J 2619-01  onto the outer end of J 41398  . See Special Tools .
  10. Use J 2619-01  to remove the CV joint from the shaft. See Special Tools .
  11. Remove J 2619-01  and J 41398  from the CV joint. See Special Tools .
    12. IMPORTANT: Never reuse the retaining ring.
  12. Remove the retaining ring from the shaft. Discard the retaining ring.
  13. Remove the CV joint seal (1) from the shaft.
    14. Fig 5: Tapping Gently On Brass Drift With A Hammer In Order To Tilt Cage
    GM211933Courtesy of GENERAL MOTORS CORP.
  14. Place a brass drift against the CV joint cage (1).
  15. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
  16. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts.
  17. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
  18. Repeat this process to remove all 6 balls.
    19. Fig 6: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
  19. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1). At the same time, align the cage windows with the lands of the outer race (2).
  20. Lift out the cage (4) and the inner race.
    21. Fig 7: View Of Inner Race & Cage
    GM214947Courtesy of GENERAL MOTORS CORP.
  21. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
  22. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
  23. Dry all the parts.
  24. Check the CV joint assembly for unusual wear, cracks, or other damage.
  25. Replace any damaged parts.
  26. Clean the shaft. Use a wire brush to remove any rust in the seal mounting area (grooves).
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