Aurora 2001-2003

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
     
    Swage ring
     
    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
     
    Trilobal tri-pod bushing from the housing
     
    Inboard spacer ring slide, it rearward on the shaft
     
    Outboard retaining ring
     
    Tri-pod joint spider assembly
     
    Inboard spacer ring and CV-joint boot

    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Positioning the inner CV-joint boot seal and swage ring-Inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. View of the swage ring crimping tool-Inner (tri-pod) joint



    Click image to see an enlarged view

    Fig. Boot measurement-Inner (tri-pod) joint



    Click image to see an enlarged view

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

     

  4.  

To install:

  1. Install or connect the following:

    Swage ring clamp
     
    CV-joint boot
     

  2.  
  3. Position the CV-joint boot seal into the axle shaft-s joint seal groove and align the swage ring clamp on the boot.
  4.  
  5. Secure the swage ring clamp as follows:
    1. Mount the lower half of tool J-41048 in a vise.
    2.  
    3. Position the outboard of the halfshaft in the tool.
    4.  
    5. Position the upper end of tool J-41048 onto the lower half.
      WARNING
      Make sure that there are no pinch points on the inboard seal.




    6.  
    7. Insert both bolts and tighten by hand until snug.
    8.  
    9. Tighten each bolt 180 degree ( 1 / 2 ) turn at a time, alternating between the bolts, until both sides are bottomed.
    10.  
    11. Remove the tool.
    12.  

  6.  
  7. Install or connect the following:
    NOTE
    Make sure the boot lies flat against the trilobal bushing.



    Inboard spacer ring slide it rearward on the shaft
     
    Tri-pod joint spider assembly onto the shaft
     
    Outboard retaining ring into the axle shaft groove
     
    Tri-pod joint spider assembly, slide it against the outboard retaining ring
     
    Inboard spacer ring
     
    1 / 2 kit grease into the boot
     
    1 / 2 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 large CV-joint boot clamp to 130 ft. lbs. (176 Nm).
  12.  
  13. Install or connect the following:

    Halfshaft
     
    Front wheel
     

  14.  

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

    Front wheel
     
    Halfshaft
     
    Swage ring
     
    Large boot clamp
     
    CV-joint boot, slide it away from the CV-joint
     
    CV-joint assembly by spreading the inner race-to-axle shaft retaining ring ears
     
    CV-joint boot from the axle shaft
     

  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. Disconnecting the outer CV-joint from the axle shaft



      Click image to see an enlarged view

      Fig. Tilting the cage-Outer CV-joint



      Click image to see an enlarged view

      Fig. View the cage and inner race-Outer CV-joint



      Click image to see an enlarged view

      Fig. Positioning the boot-Outer CV-joint

    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 or connect the following:

    1 / 2 kit grease into the CV-joint boot
     
    1 / 2 kit grease into the CV-joint
     
    Swage ring clamp
     
    CV-joint boot
     
    CV-joint onto the axle shaft until the retaining ring seats into the groove
     

  8.  
  9. Position the CV-joint boot seal into the axle shaft-s joint seal groove and align the swage ring clamp on the boot.
  10.  
  11. Secure the swage ring clamp as follows:
    1. Mount the lower half of tool J-41048 in a vise.
    2.  
    3. Position the outboard of the halfshaft in the tool.
    4.  
    5. Position the upper end of tool J-41048 onto the lower half.
      WARNING
      Make sure that there are no pinch points on the inboard seal.




    6.  
    7. Insert both bolts and tighten by hand until snug.
    8.  
    9. Tighten each bolt 180 degree ( 1 / 2 ) turn at a time, alternating between the bolts, until both sides are bottomed.
    10.  
    11. Remove the tool.
    12.  

  12.  
  13. Install or connect the following:
    NOTE
    Make sure the boot lies flat against the outer race.



    New large seal clamp onto the CV-joint boot
     
    CV-joint boot/clamp, slide it into place over the outer race with the seal lip in the groove
     

  14.  
  15. Using a crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. lbs. (176 Nm).
  16.  
  17. Install or connect the following:

    Halfshaft
     
    Front wheel
     

  18.  

 
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