Cavalier, Sunfire 2001-2005

CV-Joints

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Overhaul



Inner CV-Joint & Boot
2.2L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft
     
    Small CV-joint boot clamp
     
    Large CV-joint boot clamp
     
    CV-joint boot by sliding it away from the tri-pod joint
     
    Inboard spacer ring
     
    Outboard retaining ring
     
    Tri-pod joint spider assembly by tapping it from the halfshaft with a brass drift
     
    Tri-pod spider retaining ring
     
    Trilobal tri-pod bushing from the housing
     
    CV-joint boot

    Click image to see an enlarged view

    Fig. CV-joint boot measurement-Inner (tri-pod) joint-2.2L engine

     

  4.  

To install:

  1. Install or connect the following:

    Small boot clamp
     
    CV-joint boot
     
    New inboard spacer ring slide it rearward on the shaft past the 2nd groove
     
    Tri-pod joint spider assembly onto the shaft
     

  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 the spider assembly passes the 2nd groove.
      WARNING
      When assembling the tri-pod assembly onto the halfshaft, do not exceed 4,000 lbs. pressure.

    6.  

  4.  
  5. Remove the halfshaft from the shop press and place it in vise.
  6.  
  7. Install or connect the following:

    New outboard retaining ring into the axle shaft groove
     
    Tri-pod joint spider assembly, slide it against the outboard retaining ring using a brass drift
     

  8.  
  9. Seat the inboard spacer ring in the proper groove.
  10.  
  11. Slide the CV-joint boot into place and crimp the small boot clamp.
  12.  
  13. Install or connect the following:
    NOTE
    Make sure the boot lies flat against the trilobal bushing.



    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
     

  14.  
  15. Position the CV-joint boot so it measures or 3.7 in. (95.7).
  16.  
  17. Using a Crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm).
  18.  
  19. Crimp the large CV-joint boot clamp.
  20.  
  21. Install the halfshaft and the front wheel.
  22.  

2.4L Engine
  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
     
    Snapring from the stub shaft
     
    Small CV-joint boot clamp
     
    Large CV-joint boot clamp
     
    CV-joint boot by sliding it away from the tri-pod joint
     

  4.  
  5. Install a Stub Shaft Removal tool J-38868-A to the stub shaft snapring groove.
  6.  
  7. Using a slide hammer puller, pull the stub shaft from the tri-pod housing.
  8.  
  9. Remove or disconnect the following:

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

    Click image to see an enlarged view

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

     

  10.  

To install:

  1. Install or connect the following:

    New snapring onto the stub shaft
     
    Small boot clamp
     
    CV-joint boot
     

  2.  
  3. Using a Crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm).
  4.  
  5. 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, past the 2nd groove
     
    Tri-pod joint spider assembly onto the shaft until it passes the 2nd groove
     
    Outboard retaining ring into the axle shaft groove
     
    Tri-pod joint spider assembly, slide it against the outboard retaining ring
     
    Inboard spacer ring, seat it in the groove
     
    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
     

  6.  
  7. Position the CV-joint boot so it measures 4.9 in. (125mm).
  8.  
  9. Crimp the large CV-joint boot clamp.
  10.  
  11. Install the halfshaft and the front wheel.
  12.  

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

    Front wheel
     
    Halfshaft and 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
     

  4.  
  5. Perform the following:
    1. Choose a reference mark on the halfshaft.
    2.  
    3. Measure the distance between the reference mark and the CV-joint inner race face; retain this measurement.
    4.  

  6.  
  7. Attach CV Puller tool J-41398 to the outer race threaded area.
  8.  
  9. Remove or disconnect the following:

    CV-joint outer race from the halfshaft using a slide hammer puller
     
    CV Puller tool J-41398 and slide hammer puller from the outer race
     
    Retaining ring from the halfshaft
     
    CV-joint boot from the halfshaft
     

  10.  
  11. 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.  

  12.  
  13. 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. Measuring the halfshaft-to-inner race reference distance-Outer CV-joint



      Click image to see an enlarged view

      Fig. Removing the outer race from the halfshaft-Outer CV-joint



      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. Crimping the small boot clamp-Outer CV-joint



      Click image to see an enlarged view

      Fig. Positioning the CV boot onto the outer race-Outer CV-joint



      Click image to see an enlarged view

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

    8.  

  14.  

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 kit grease into the CV-joint.
  8.  
  9. Install or connect the following:
    WARNING
    When installing the outer race assembly onto the halfshaft, do not exceed 4,000 lbs. pressure.



    Small ring clamp on the CV boot, do not crimp at this time
     
    CV-joint boot and slide it up the shaft to expose the reference mark
     
    New retaining ring on the halfshaft
     
    Large ring clamp on the CV boot
     
    Outer race assembly by pressing it onto the halfshaft until the ring engages
     

  10.  
  11. Measure the distance between the reference mark and the CV-joint inner race face; the distance must be +/- 0.039 in. (1mm) of the original measurement. If the measurement is not correct, repress the outer race assembly and recheck it.
  12.  
  13. 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.

  14.  
  15. Using a Crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm).
  16.  
  17. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.
  18.  
  19. Install 1 / 2 of the kit grease into the CV-joint boot.
  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.
  28.  

 
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