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Assembly Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Place the new small seal clamp (2) onto the small end of the joint seal (1). Compress the joint seal (1) and small seal clamp (2) onto the halfshaft bar.
  2. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.
    3. Fig 1: Positionng Small End Of Joint Seal Into Joint Seal Groove
    GM386688Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Secure the small seal clamp (1) with J 35910  , or equivalent, a breaker bar, and a torque wrench.

    Tighten:  Tighten the small seal clamp (1) to 136 N.m (100 lb ft).

  4. Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached.
    5. Fig 2: View Of CV Joint Seal Retaining Clamp
    GM214026Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Assemble the tripot joint with the convolute retainer in the correct position, as illustrated.
  5. Install the convolute retainer tool over the inboard joint seal, being sure to capture the following convolutions:
    • 2-5 for the 1500 model (except 1500 HD)
    • 2-4 for the 1500 HD, 2500, 3500, and Hummer H2 models.
    6. Fig 3: Tripot Joint W/Convolute Retainer
    GM214938Courtesy of GENERAL MOTORS CORP.
  6. Install the tripot spider assembly (3) onto the halfshaft bar (2).
  7. Install the spacer ring (1) in the groove at the end of the halfshaft bar (2).
    8. Fig 4: Spacer Ring, Halfshaft Bar & Tripot Spider Assembly
    GM212035Courtesy of GENERAL MOTORS CORP.
  8. Pack the tripot seal (4) and the tripot housing (1) with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
    9. Fig 5: Tripot Housing, Tripot & Seal
    GM212048Courtesy of GENERAL MOTORS CORP.
  9. Assemble the tripot housing and the tripot seal using the following procedure:
    1. Pinch the swage ring (2) slightly by hand in order to distort it into an oval shape.
    2. Slide the distorted swage ring (2) over the large diameter of the seal.
    3. Place the tripot housing over the spider assembly.
    4. Install the seal onto the tripot housing.
    5. Align the tripot seal (1), with the swage ring (2) in place, over the flat area on the tripot housing (3).
    10. Fig 6: Assembling The Tripot Housing And The Tripot Seal
    GM214957Courtesy of GENERAL MOTORS CORP.
  10. For the 1500 models (except 1500 HD), assemble the bolts and the support plate to the base of the J-36652-01 and secure the base in a vise.
  11. For the 1500 HD, 2500, 3500, and HUMMER H2 models, assemble the bolts and the support plate to the base of the J 36652-98  and secure the base in a vise.
    12. Fig 7: Assembling The Bolts And The Support Plate To The Base Of The J 36652-98
    GM214958Courtesy of GENERAL MOTORS CORP.
  12. Position the inboard end (tripot end) of the halfshaft assembly into the base of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98  for the 1500 HD, 2500, 3500 and Hummer H2 models.
  13. Install the top half of the J-36652-01 for the 1500 models (except 1500 HD) or J 36652-98  for the 1500 HD, 2500, 3500 and HUMMER H2 models.
  14. Align the swage ring (2) and the swage ring clamp.
  15. Insert the bolts.

    Tighten:  Hand tighten the bolts until the bolts are snug.

  16. Align the following during this procedure:
    • The tripot boot (3)
    • The tripot housing (1)
    • The swage ring (2)

      Tighten:  Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half.

    • Loosen the bolts and remove the halfshaft assembly from the tool.
    17. Fig 8: Installing The Swage Ring
    GM212054Courtesy of GENERAL MOTORS CORP.
  17. Inspect the inboard stroke position.
    • Use measurement A for the 1500 models (except 1500 HD).
    • Use measurement B for the 1500 HD, 2500, 3500, and Hummer H2 models.
    18. Fig 9: Inspecting Inboard Stroke Position
    GM214960Courtesy of GENERAL MOTORS CORP.
  18. Remove the convolute retainer tool from the boot.
    19. Fig 10: Removing Convolute Retainer Tool
    GM214966Courtesy of GENERAL MOTORS CORP.
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