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Home >> GMC >> 2006 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1135 (Wheel Drive Shafts) >> Repair Instructions >> Front Wheel Drive Shaft Outer Joint Boot Replacement >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2008 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Positioning Cage So Larger Radius Corners Of Cage Windows Are Up
    GM174613Courtesy of GENERAL MOTORS CORP.
  1. Position the cage so the larger radius corners of the cage windows are up.
  2. Position the inner race 90 degrees to the centerline of the cage.
  3. Begin to insert the inner race up through the bottom of the cage.
  4. Align a land of the inner race to a window of the cage.
  5. Insert the inner race land into the cage window.
  6. Rotate the remainder of the inner race into the cage.
  7. Rotate the inner race within the cage so that the grooved surface of the inner race is facing up.
    8. IMPORTANT: Ensure that the inner race is fully assembled into the cage.
  8. Align the inner race ball tracks with the cage windows.
    9. Fig 2: Positioning Cage & Inner Race 90 Degrees To Centerline Of Outer Race
    GM174610Courtesy of GENERAL MOTORS CORP.
  9. Wrap a shop towel around the joint outer race splined shaft.
  10. Place the outer race vertically in a bench vise.
  11. Position the cage and inner race 90 degrees to the centerline of the outer race.
  12. Align 2 cage windows at 0 and 180 degrees, within the outer race.

    Rotate the inner race and cage assembly downward in the vertical plane.

    13. Fig 3: Removing/Install Ball From Cage & Inner Race
    GM174607Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The inner race ring groove must be positioned down.
  13. Position the cage and inner race so they are level.
  14. Align the cage windows and inner race ball tracks with the outer race ball tracks.
  15. Position a cage window and inner race ball track for ball installation.
    1. Press down on the cage following one of the outer race ball tracks. The opposing cage window and inner race ball track will be accessible for ball installation.
    2. After installing the first ball, use a brass drift and a hammer to tap gently on the cage, in order to drive the cage and inner race down completely.
    16. IMPORTANT: No gap should exist between the ball and the inner race ball track.
  16. Insert a ball through the cage window onto the inner race ball track.

    Tap the ball lightly with a plastic tipped hammer.

  17. Position the cage and inner race so they are level.
    18. Fig 4: View Of Ball Removal/Installation Sequence
    GM174670Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The ball installation sequence must be followed as shown.
  18. Repeat steps 17-19 in the installation sequence as shown, until all of the balls are installed.
    19. Fig 5: Applying Grease To Outer Joint
    GM174615Courtesy of GENERAL MOTORS CORP.
  19. Insert approximately 60 percent of the grease from the service kit into the outer joint.
    1. Spread 60 percent of the grease onto the ball tracks, the balls, the cage and the inner race.
    2. Spread the remainder of the grease into the bottom of the outer race.
  20. Remove the outer joint from the bench vise.
    21. Fig 6: Removing/Installing Axle Shaft Boot Seal
    GM174617Courtesy of GENERAL MOTORS CORP.
  21. Wrap a shop towel around the axle shaft.
  22. Place the wheel drive shaft horizontally in a bench vise.
  23. Install a new small seal retaining clamp onto the axle shaft.
  24. Install the seal onto the axle shaft.
    25. Fig 7: View Of Axle Shaft Retaining Ring
    GM174601Courtesy of GENERAL MOTORS CORP.
  25. Install a new retaining ring to the axle shaft.
    26. Fig 8: View Of Axle Shaft Retaining Ring
    GM174620Courtesy of GENERAL MOTORS CORP.
  26. Position the outer joint horizontally.
  27. Engage the inner race splines onto the axle shaft splines.
  28. Compress the axle shaft retaining ring.
    1. Press the end of the retaining ring, using a flat-bladed tool, into the axle shaft groove while firmly pressing the outer joint onto the axle shaft.
    2. Continue to work around the retaining ring, until it is compressed.
    29. Fig 9: Identifying Outer Joint Threaded Shaft
    GM174623Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The axle shaft and inner race must be fully seated to each other.
  29. Install the outer joint to the axle shaft.
    1. Position a wood block over the end of the outer joint threaded shaft.
    2. Use a hammer to drive the outer joint onto the shaft.
    3. Continue to drive the outer joint until the outer joint seats fully onto the axle shaft.
    30. Fig 10: Inserting Remaining Grease From Service Kit Into Seal
    GM174625Courtesy of GENERAL MOTORS CORP.
  30. Insert the remaining grease from the service kit into the seal.
    31. Fig 11: Inner Joint Seal, Small Seal Clamp, & Inner Joint Seal Groove
    GM1208666Courtesy of GENERAL MOTORS CORP.
  31. Position the small seal retaining clamp (2) into the boot groove.
  32. Position the boot and small retaining clamp to the axle shaft boot groove (3) as shown.
    33. Fig 12: Using J 42572 To Crimp Seal Retaining Clamp
    GM174632Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
    IMPORTANT: The seal retaining clamp must not be over-tightened or under-tightened.
  33. Using the J 42572  , crimp the small seal retaining clamp. See Special Tools .

    Tighten:  Tighten the small seal clamp until there is a gap of 1 mm (0.039 in).

    34. Fig 13: View Of Large Seal Retaining Clamp, Seal & Boot Groove
    GM1208968Courtesy of GENERAL MOTORS CORP.
  34. Position the large seal retaining clamp (1) onto the seal (2).
  35. Position the seal and large retaining clamp to the joint outer race (3) as shown.
    36. Fig 14: Using J 42572 To Crimp Seal Retaining Clamp
    GM174632Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The seal must not be dimpled, stretched or otherwise deformed.
  36. Inspect the boot for proper shape.

    If the boot is not shaped correctly, equalize the pressure in the boot by lifting the boot edge slightly and shape the properly by hand.

  37. Inspect the boot for damage.

    If the boot has been cut or punctured during assembly, you must discard and replace the boot.

    38. IMPORTANT: The seal retaining clamp must not be over-tightened or under-tightened.
  38. Using the J 42572  , crimp the large seal retaining clamp. See Special Tools .

    Tighten:  Tighten the large seal clamp until there is a gap of 1 mm (0.039 in).

    The clamping hold time must be no less than 2 seconds.

  39. Inspect the outer joint for smooth operation. This will also distribute the grease within the joint.
    1. Hold the wheel drive shaft vertically, with the outer joint at the bottom.
    2. Rotate the wheel drive shaft 4 or 5 times in a circular motion.
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