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Home >> Saturn >> 2003 >> Ion 1 Standard >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Axle Shafts >> Wheel Drive Shafts >> Repair Instructions >> Wheel Drive Shaft Inner Joint and Seal Replacement >> Assembly Procedure

Assembly Procedure

    Fig 1: Measuring Clamp End Gap
    GM872889Courtesy of GENERAL MOTORS CORP.
  1. Install the small boot retaining clamp on the neck of the inboard boot. Do not crimp.
  2. Slide the inboard boot onto the axle shaft.
    3. IMPORTANT: The clamp must be in the correct orientation during the crimp operation, to ensure a proper circumference seal.
  3. Crimp the boot retaining clamp with the SA9203C  . See Special Tools .
  4. Measure the clamp end gap (a), taking care not to exceed 3 mm (0.118 in). Repeat the previous step as necessary.
  5. Slide the tripot joint spider assembly past the spider retaining ring groove until seated against the shoulder.
    6. Fig 2: View Of Tripot Joint Spider Assembly & Housing
    GM872881Courtesy of GENERAL MOTORS CORP.
  6. Install the spider retaining ring in the groove of the axle shaft with the SA9198C  . See Special Tools .
  7. Place approximately half of the grease from the service kit in the inboard boot. Use the remainder of the grease to repack the housing.
    8. IMPORTANT: The CV joint must be assembled with the convoluted retainer in position. Boot damage will result if the joint is not assembled correctly.
  8. Install the trilobal tripot bushing to the housing. Ensure the trilobal tripot bushing is flush with the face of the housing.
  9. Position the larger new clamp on the inboard boot.
  10. Slide the housing over the tripot joint spider assembly on the axle shaft.
    11. Fig 3: Identifying Axle Shaft/CV Joint Assembly Compontents And Installed Boot Measurement Dimension
    GM221916Courtesy of GENERAL MOTORS CORP.
  11. Slide the large diameter of the inboard boot (2), with the larger clamp in place (3), over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove (4).
    12. Fig 4: Installing Large Boot Retaining Clamp
    GM872886Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The inboard boot must not be dimpled, stretched out or out of shape in any way. If the inboard boot is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large boot opening and the trilobal tripot bushing to equalize the pressure. Shape the inboard boot properly by hand. Remove the tool.
  12. Place the large boot retaining clamp around the boot and close using the SA9161C  . See Special Tools .
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