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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 >> Disassembly Procedure

Disassembly Procedure

    Fig 1: Removong Race Retaining Ring
    GM221901Courtesy of GENERAL MOTORS CORP.
  1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the boot retaining clamp.
  2. Remove the small boot retaining clamp from the axle shaft with a hammer and flat blade tool. Discard the boot retaining clamp.
  3. Separate the boot (5) from the CV joint outer race at large diameter and slide the boot away from joint along bar (4).
  4. Wipe the grease from the face of the CV joint inner race.
  5. Using a rubber mallet or block of wood and hammer, tap on the CV joint to remove the CV joint from the axle.
  6. Remove the boot from the bar.
  7. Fig 2: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage
    GM211933Courtesy of GENERAL MOTORS CORP.
  8. Use a brass drift and a hammer in order to gently tap on the CV joint cage (1) until the cage is tilted enough to remove the first chrome alloy ball (2).
  9. Tilt the cage in the opposite direction in order to remove the opposing ball.
  10. Repeat this process until all 6 balls are removed.
  11. Fig 3: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage
    GM214946Courtesy of GENERAL MOTORS CORP.
  12. Position the CV joint cage (4) and the CV joint inner race 90 degrees to the centerline of the CV joint outer race (1).

    Align the CV joint cage windows (3) with the lands of the CV joint outer race (2).

  13. Remove the CV joint cage (4) and the CV joint inner race from the CV joint outer race (1).
  14. Fig 4: View Of Inner Race & Cage
    GM214947Courtesy of GENERAL MOTORS CORP.
  15. Rotate the CV joint inner race 90 degrees to the centerline of the CV joint cage with the lands of the CV joint inner race (1) aligned with the windows of the CV joint cage (2).
  16. Pivot the inner race into the cage window and remove the inner race.
  17. Clean the inner and outer race assemblies, the CV joint cage and the balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
  18. Dry all of the parts.