LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1013 (Wheel Drive Shafts) >> Repair Instructions >> Wheel Drive Shaft Outer Joint and Seal Replacement >> Disassembly Procedure

Disassembly 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.
IMPORTANT: Use caution when using the hand grinder by the CV joint outer race (1).
  1. Use a hand grinder to cut through the swage ring (2).
  2. Use side cutters to cut off the small boot clamp (4).
    3. Fig 1: CV Joint Outer Race, Swage Ring, Boot & Small Boot Clamp
    GM211906Courtesy of GENERAL MOTORS CORP.
  3. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1).
  4. Wipe all grease away from the face of the CV joint.
  5. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2).
  6. Spread the snap ring ears apart using J 8059  (or equivalent).
    Fig 2: Spreading The Snap Ring Ears Apart Using J 8059
    GM212684Courtesy of GENERAL MOTORS CORP.
  7. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4).
  8. Discard the old CV joint boot (5).
  9. Place a brass drift against the CV joint cage (1).
  10. Tap gently on the brass drift with a hammer in order to tilt the cage (1).
  11. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts.
  12. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).
  13. Repeat this process to remove all six of the balls.
    14. Fig 3: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage
    GM211933Courtesy of GENERAL MOTORS CORP.
  14. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2).
  15. Lift out the cage (4) and the inner race.
    16. Fig 4: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
  16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.
    17. Fig 5: View Of Inner Race & Cage
    GM214947Courtesy of GENERAL MOTORS CORP.
  17. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
    1. The inner and outer race assemblies
    2. The CV joint cage
    3. The chrome alloy balls
  18. Dry all the parts.
  19. Check the CV joint assembly for unusual wear, cracks, or other damage.
  20. Replace any damaged parts.
  21. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
scientia non olet · About LEMON Manuals