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Home >> Chevrolet >> 2012 >> Cruze Eco, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 114 (Wheel Drive Shafts) >> Repair Instructions >> Wheel Drive Shaft Outer Joint and Boot Replacement (Delphi) >> Assemble Procedure

Assemble Procedure

WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Inner Race & Cage
    GM214947Courtesy of GENERAL MOTORS CORP.
  1. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race.
  2. Hold the inner race 90 degrees to the centerline of the cage with the lands of the inner race (1) aligned with the windows of cage (2).
  3. Insert the inner race into the cage.
    4. Fig 2: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
  4. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows (3) with the lands of the outer race (2).
    5. NOTE: Ensure that the inner race is oriented the same as prior to disassembly. Use the reference mark placed earlier.
  5. Install the cage and the inner race into outer race.
    6. Fig 3: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage
    GM211933Courtesy of GENERAL MOTORS CORP.
  6. Place a brass drift against the CV joint cage (1).
  7. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
  8. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts.
  9. Repeat this process to install all 6 balls.
  10. Pack the CV joint with half of the grease supplied in the service kit.
    11. Fig 4: Identifying Wheel Drive Shaft Outer Joint Components
    GM621765Courtesy of GENERAL MOTORS CORP.
  11. Install the new swage ring (2) on the neck of the seal (3). Do not crimp.
  12. Clean the shaft (1). Use a wire brush to remove any rust in the seal mounting area (grooves).
  13. Slide the CV joint seal (3) onto the shaft (1). Expose the reference mark (4) by sliding the CV joint seal (3) up the shaft (1) toward the tripot end.
    14. Fig 5: View Of Arbor Press
    GM256104Courtesy of GENERAL MOTORS CORP.
  14. Position the large seal retaining clamp around the joint seal.
  15. Place the new retaining ring onto the shaft.
  16. While supporting the tripot assembly, place the wheel drive shaft assembly onto the arbor press with the CV assembly under the press head.
  17. Lower the arbor press head onto the CV joint assembly until the press cannot move any further. This ensures that the retaining ring engages in the inner race. Do not exceed 1 779 N (4,000 lb) press load during assembly.
  18. Remove the wheel drive shaft assembly from the arbor press.
    19. Fig 6: Placing Reference Mark (B) The Halfshaft Bar
    GM256095Courtesy of GENERAL MOTORS CORP.
  19. Measure the distance between the reference mark on the shaft (B) and the face of the CV joint inner race (1).
  20. Compare the mark with the measurement made before disassembly.
  21. Repeat the previous 4 steps if the current measurement does not match the measurement made before disassembly.
    22. Fig 7: View Of Outboard Seal, Seal Groove & Eared Clamp
    GM214024Courtesy of GENERAL MOTORS CORP.
  22. Place the new swage ring (2) onto the small end of the joint boot (1). Slide the boot (1) and the swage ring (2) onto the half shaft bar.
  23. Position the small end of the boot (1) into the boot groove (3) on the half shaft bar.
    24. Fig 8: Mounting Drive Axle Swage Ring Clamp
    GM1550610Courtesy of GENERAL MOTORS CORP.
  24. Mount DT-47732  in a vise and proceed as follows: See Special Tools .
    1. Position the outboard end (1) of the wheel drive shaft assembly in tool.
    2. Align the top of boot neck on the bottom die using the indicator.
    3. Place the top half of the DT-47732  on the lower half of the DT-47732  . See Special Tools .
    4. Before proceeding, ensure there are no pinch points on the boot. This could cause damage to the boot.
    5. Insert the bolts (2).
    6. Tighten the bolts by hand until snug.
    25. Fig 9: Identifying Halfshaft Inboard Seal & Swage Ring
    GM221918Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  25. Align the following items:
    • The shaft out board boot (1)
    • The shaft boot grooves
    • The swage ring (2)

      Tighten:  Tighten each bolt of DT-47732  180 degrees at a time using a ratchet wrench. See Special Tools . Alternate between each bolt until both sides are bottomed.

      Place the remaining grease from the service kit inside the seal.

    26. Fig 10: Measuring CV Outer Joint Assembly
    GM256106Courtesy of GENERAL MOTORS CORP.
  26. Mount DT-47732  in a vise and proceed as follows: See Special Tools .

    Measure approximately 17.5 mm (11/16 in) up from the bottom edge of the CV outer joint assembly.

  27. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of CV joint.
    28. NOTE: The CV joint seal must not be dimpled, stretched or out of shape in any way. If seal is not shaped correctly, equalize pressure in the seal and shape the seal properly by hand.
  28. Locate the seal lip to the ridge of the CV outer joint assembly as measured in the previous step.
    29. Fig 11: View Of Outboard Seal, Large Seal Retaining Clamp & CV Joint Outer Race
    GM245263Courtesy of GENERAL MOTORS CORP.
  29. Crimp seal retaining clamp (1) with J 35910  , a breaker bar (3), and a torque wrench (2). See Special Tools .

    Tighten:  Tighten seal retaining clamp to 176 N.m (130 lb ft).

  30. Check the gap dimension. Continue tightening until the correct gap dimension is reached. Dimension a = 2.3 mm (0.091 in).
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