Alero, Grand Am 1999-2005

CV-Joints

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Overhaul



Inner CV-Joint & Boot
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft and place it in a vise
     
    Small CV-joint boot clamp
     
    Large CV-joint boot clamp
     
    CV-joint boot by sliding it away from the tri-pod joint
     
    Tri-pod housing from the tri-pod spider
     
    Inboard spacer ring and slide it rearward on the shaft, using snapring pliers
     
    Outboard retaining ring
     
    Tri-pod joint spider assembly by tapping it from the halfshaft with a brass drift
     
    Inboard tri-pod spider retaining ring
     
    Trilobal tri-pod bushing from the housing
     
    CV-joint boot
     

  4.  
  5. Thoroughly clean and inspect all parts.

    Click image to see an enlarged view

    Fig. Exploded view of the inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. Crimping the small CV-joint boot ring-Inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. CV-joint boot measurement-Inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. Latching the large CV-joint boot ring-Inner (tri-pod) joint

  6.  

To install:

  1. Install or connect the following:

    Small boot clamp
     
    CV-joint boot
     
    New tri-pod spider retaining ring onto the halfshaft, slide it past the 2nd ring groove
     

  2.  
  3. Assemble the tri-pod spider assembly onto the halfshaft as follows:
    1. Position the tri-pod spider assembly onto the shop press plate.
    2.  
    3. Position the halfshaft onto the tri-pod spider assembly, in the shop press.
    4.  
    5. Press the halfshaft into the tri-pod spider assembly until it passes the 2nd ring groove.
    6.  

  4.  
  5. Remove the halfshaft from the shop press.
  6.  
  7. Install or connect the following:
    NOTE
    Make sure the boot lies flat against the trilobal bushing.



    Outboard retaining ring into the axle shaft groove using snapring pliers
     
    Tri-pod joint spider assembly, slide it against the outboard retaining ring
     
    Inboard spacer ring, seat it in the groove
     
    1 / 2 of the kit grease into the boot
     
    1 / 2 of the kit grease into the tri-pod housing
     
    Trilobal tri-pod bushing flush with the tri-pod housing face
     
    New large seal clamp onto the CV-joint boot
     
    Tri-pod housing, slide it over the tri-pod joint spider assembly
     
    CV-joint boot/clamp, slide it into place, over the trilobal tri-pod bushing with the seal lip in the groove
     

  8.  
  9. Position the CV-joint boot so it measures 4.9 in. (125mm).
  10.  
  11. Using a crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm).
  12.  
  13. Using a crimp tool, latch the large CV-joint boot clamp.
  14.  
  15. Install the halfshaft and the front wheel.
  16.  

Outer CV-Joint
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft, position it in a vise
     
    Large CV-joint boot clamp
     
    Small CV-joint boot clamp
     
    CV-joint boot and slide it back on the shaft
     
    Outer race from the halfshaft, by spreading retaining ring
     
    Retaining ring from the halfshaft
     
    CV-joint boot from the halfshaft and discard it if damaged
     

  4.  
  5. Disassemble the chrome alloy balls from the CV-joint cage as follows:
    1. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage.
    2.  
    3. Remove the 1st chrome alloy ball from the cage.
    4.  
    5. Tilt the cage in the opposite direction.
    6.  
    7. Remove the opposite chrome alloy ball.
    8.  
    9. Repeat the procedure until all 6 balls are removed.
    10.  

  6.  
  7. Disassemble the CV-joint cage and inner race as follows:
    1. Pivot the cage and race 90 degrees to the center line of the outer race.
    2.  
    3. Align the cage windows with outer race lands.
    4.  
    5. Remove the cage from the outer race.
    6.  
    7. Rotate the inner race upward and remove it from the cage.

      Click image to see an enlarged view

      Fig. Exploded view of the halfshaft assembly



      Click image to see an enlarged view

      Fig. Disconnecting the outer CV-joint from the axle shaft

    8.  

  8.  

To install:

  1. Lubricate the parts with a light coat of grease.
  2.  
  3. Assemble the CV-joint cage and inner race, as follows:
    1. Rotate the inner race 90 degrees to the cage centerline.
    2.  
    3. Align the cage windows with inner race lands.
    4.  
    5. Insert the inner race into the cage by rotating the inner race downward.
    6.  
    7. Insert the cage/inner race into the outer race.
    8.  

  4.  
  5. Assemble the chrome alloy balls into the CV-joint cage, as follows:
    1. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage.
    2.  
    3. Insert the 1st chrome alloy ball into the cage.
    4.  
    5. Tilt the cage in the opposite direction.
    6.  
    7. Insert the opposite chrome alloy ball.
    8.  
    9. Repeat the procedure until all 6 balls are inserted.
    10.  

  6.  
  7. Install 1 / 2 of the grease provided, into the CV-joint.
  8.  
  9. Install or connect the following:

    Small ring clamp on the CV boot
     
    New retaining ring on the halfshaft
     
    Large ring clamp on the CV boot
     
    Outer race assembly onto the halfshaft until the ring engages the halfshaft groove
     

  10.  
  11. Slide the small end of the CV-joint boot/clamp into place, with the seal lip in the halfshaft groove.
    NOTE
    Make sure the boot lies flat against the halfshaft.

  12.  
  13. Using a crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm).
  14.  
  15. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.
  16.  
  17. Install 1 / 2 kit grease into the CV-joint boot.
  18.  
  19. Measure approximately 0.687 in. (17.5mm) up from the bottom edge of the outer CV-joint assembly.
  20.  
  21. Slide the large end of the CV boot/clamp into place, with the seal lip in place over the outer race.
    NOTE
    Make sure the boot lies flat against the outer race.

  22.  
  23. Using a crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. lbs. (176 Nm).
  24.  
  25. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tightening the clamp until it is.
  26.  
  27. Install the halfshaft and the front wheel.

    Click image to see an enlarged view

    Fig. Crimping the small boot clamp-Outer CV-joint



    Click image to see an enlarged view

    Fig. Crimping the large boot clamp-Outer CV-joint

  28.  

 
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