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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 Outer Joint and Seal Replacement >> Assembly Procedure

Assembly Procedure

    Fig 1: View Of Boot, Retaining Clamp, & Groove
    GM900963Courtesy of GENERAL MOTORS CORP.
  1. Install the new boot retaining clamp (2) on the neck of the boot. Do not crimp.
  2. Slide the boot (1) onto the axle shaft and position the neck of the boot in the boot groove (3) on the bar.
    3. Fig 2: Measuring Clamp End Gap
    GM872889Courtesy of GENERAL MOTORS CORP.
  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. Check the gap dimension, continue tightening until the gap dimension is reached.
    6. Fig 3: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
  6. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race.
  7. Hold the inner race 90 degrees to centerline of cage (4) with the lands of the inner race (2) aligned with the windows (3) of the cage.
  8. Insert the inner race into the cage.
    9. IMPORTANT: Ensure that the retaining ring side of the inner race faces the axle shaft.
  9. Place the cage and the inner race into the outer race.
  10. Insert the first chrome ball then tilt the cage in the opposite direction in order to insert the opposing ball.
  11. Repeat this process until all 6 balls are in place.
  12. Place approximately half the grease from the service kit inside the boot and pack the CV joint with the remaining grease.
    13. Fig 4: Installing CV Joint Onto Bar
    GM872890Courtesy of GENERAL MOTORS CORP.
  13. Push the CV joint (2) onto the bar (1) until the retaining ring is seated in the groove on the bar.
    14. IMPORTANT: Ensure that the boot is not dimpled, stretched, or out of shape. If the boot is not shaped correctly, equalize the pressure in the boot and shape the boot properly by hand.
  14. Slide large diameter of the boot with the large boot retaining clamp in place over the outside of the CV joint outer race.
  15. Crimp the retaining clamp using the SA9161C  . See Special Tools .
    16. Fig 5: Measuring CV Joint Clamp End Gap
    GM872891Courtesy of GENERAL MOTORS CORP.
  16. Crimp the boot retaining clamp using the SA9203C  . See Special Tools .
  17. Measure the clamp end gap (a), taking care not to exceed 3 mm (0.118 in). Repeat the previous step as necessary.
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