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Axle Shaft Inner Joint & Seal: Reassembly

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  1. Place the new small seal clamp onto the small end of the joint seal. Compress the joint seal and small seal clamp onto the halfshaft bar. Position the small end of the joint seal into the joint seal groove on the halfshaft bar. See Fig 1.
  2. Secure the small seal clamp with Drive Axle Seal Clamp Pliers, or equivalent, a breaker bar, and a torque wrench. Tighten the small seal clamp to specifications. See TORQUE SPECIFICATIONS . Inspect the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Gap dimension is .085" (2.15 mm). See Fig 2.
  3. Assemble the tripot joint with the convolute retainer in the correct position, as illustrated. See Fig 3. 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.
  4. Install the tripot spider assembly onto the halfshaft bar. Install the spacer ring in the groove at the end of the halfshaft bar. Pack the tripot seal and the tripot housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
  5. Assemble the tripot housing and the tripot seal using the following procedure:
    1. Pinch the swage ring slightly by hand in order to distort it into an oval shape.
    2. Slide the distorted swage ring 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, with the swage ring in place, over the flat area on the tripot housing.
  6. For the 1500 models (except 1500 HD), assemble the bolts and the support plate to the base of the Drive Axle Clamp Swage Tool and secure the base in a vise. For the 1500 HD, 2500, 3500, assemble the bolts and the support plate to the base of the Axle Swage Tool and secure the base in a vise.
  7. Position the inboard end (tripot end) of the halfshaft assembly into the base of the Drive Axle Clamp Swage Tool for the 1500 models (except 1500 HD) or Axle Swage Tool for the 1500 HD, 2500, 3500. Install the top half of the Drive Axle Clamp Swage Tool for the 1500 models (except 1500 HD) or Axle Swage Tool for the 1500 HD, 2500, 3500.
  8. Align the swage ring and the swage ring clamp. Insert the bolts. Hand tighten the bolts until the bolts are snug. Align the following during this procedure:
    • The tripot boot.
    • The tripot housing.
    • The swage ring.
    • 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.
  9. Inspect the inboard stroke position. See Fig 4.
    • Use measurement A for the 1500 models (except 1500 HD).
    • Use measurement B for the 1500 HD, 2500, 3500.
  10. Remove the convolute retainer tool from the boot.
Fig 1: Installing New Seal
G00307733Courtesy of GENERAL MOTORS CORP.
Fig 2: Checking Air Gap On Large CV Boot Clamp Ear
G99F50174Courtesy of GENERAL MOTORS CORP.
Fig 3: Positioning Special Tool
G00330059Courtesy of GENERAL MOTORS CORP.
Fig 4: Inspecting Inboard Stroke Position
G00330060Courtesy of GENERAL MOTORS CORP.
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