Corvette 1997-2005

CV-Joints

Print

Overhaul



Inner CV-Joint & Boot
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft.
  4.  
  5. Wrap a shop towel around the axle shaft.
  6.  
  7. Place the wheel driveshaft horizontally in a bench vise.
  8.  
  9. Remove the large seal retaining clamp from the CV joint seal.
  10.  
  11. Use a side cutter or other suitable tool and discard the clamp.
  12.  
  13. Remove the small seal retaining clamp from the joint seal.
  14.  
  15. Use a side cutter or other suitable tool and discard the clamp.
  16.  
  17. Separate the seal from the joint outer race at the large diameter end.

    Click image to see an enlarged view

    Fig. Separate the seal from the joint outer race at the large diameter end-inner joint

  18.  
  19. Position the seal behind the joint face.
  20.  
  21. Position the wheel driveshaft vertically in the bench vise so the inner joint is up.
  22.  
  23. Slide the joint outer race down toward the vise.
  24.  
  25. Disengage the outer race retaining ring as follows:
    1. Insert a small flat-bladed screwdriver between the retaining ring and the outer race.
    2.  
    3. Pry the retaining ring from the outer race.
    4.  
    5. Position the retaining ring along the axle shaft away from the outer race.
      NOTE
      The balls may fall out of the cage and inner race when the outer race is removed.

    6.  

  26.  
  27. Remove the outer race from the axle shaft as follows:
    1. Use the seal to catch any balls which are not retained by grease.
    2.  
    3. Lift the outer race off the axle shaft.

      Click image to see an enlarged view

      Fig. Remove the outer race from the axle shaft-inner joint



      Click image to see an enlarged view

      Fig. Remove the snapring from the axle shaft-inner joint



      Click image to see an enlarged view

      Fig. Remove the inner race from the axle shaft using a three jaw puller-inner joint



      Click image to see an enlarged view

      Fig. Remove the cage from the axle shaft-inner joint

    4.  

  28.  
  29. Remove any remaining balls from the cage and inner race.
  30.  
  31. Remove any balls caught by the seal.
  32.  
  33. Position the wheel driveshaft horizontally in the bench vise.
  34.  
  35. Remove the outer race retaining ring from the axle shaft.
  36.  
  37. Remove the snapring from the axle shaft.
  38.  
  39. Align the cage lands with the inner race ball tracks.
  40.  
  41. Reposition the cage along the axle shaft away from the inner race.
  42.  
  43. Wipe the grease from the inner race.
  44.  
  45. Remove the inner race from the axle shaft using a three jaw puller.
  46.  
  47. Remove the cage from the axle shaft.
  48.  
  49. Remove the seal from the axle shaft.
  50.  
  51. Remove the wheel driveshaft from the bench vise.
    NOTE
    All traces of old grease and any contaminates must be removed.

  52.  
  53. Clean all parts thoroughly with clean solvent.
  54.  
  55. Thoroughly air dry all the parts.
  56.  

To install:


NOTE
Protect the wheel driveshaft boots, seals and clamps from sharp objects when servicing on or near the wheel driveshaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel driveshaft.

  1. Wrap a shop towel around the axle shaft.
  2.  
  3. Place the wheel driveshaft horizontally in a bench vise.
  4.  
  5. Install a new small seal retaining clamp onto the wheel driveshaft.
  6.  
  7. Install the seal onto the axle shaft.
  8.  
  9. Install the cage onto the axle shaft so the smaller diameter end faces the vise.
    NOTE
    The inner race spline relief must face away from the end of the axle shaft.

  10.  
  11. Install the inner race onto the axle shaft as follows:
    1. Engage the inner race splines onto the axle shaft splines. Be sure to install the inner race spline relief side onto the axle shaft first.
    2.  
    3. Position a wood block squarely over the end of the inner race.
    4.  
    5. Use a hammer to begin to drive the inner race onto the axle shaft.

      Click image to see an enlarged view

      Fig. Use a hammer and a block of wood to drive the inner race onto the axle shaft-inner joint



      Click image to see an enlarged view

      Fig. Insert approximately 60 percent of the grease from the service kit into the outer race-inner joint



      Click image to see an enlarged view

      Fig. Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10 inch (2.5mm)-inner joint

    6.  
    7. Reposition the wood block along the face of the inner race to avoid the axle shaft.
    8.  
    9. Work evenly around the inner race and continue to drive the inner race, until you feel the inner race seat fully onto the axle shaft.
    10.  

  12.  
  13. Inspect to be sure that the axle shaft snapring groove is exposed.
  14.  
  15. Install the snapring to the axle shaft.
  16.  
  17. Position the cage so the cage lands align with the inner race ball tracks.
  18.  
  19. Install the cage onto the inner race.
  20.  
  21. Position the cage windows to align with the inner race ball tracks.
  22.  
  23. Insert approximately 60 percent of the grease from the service kit into the outer race.
  24.  
  25. Position the wheel driveshaft vertically in the bench vise so the inner joint end is up.
  26.  
  27. Apply a small amount of the grease from the service kit to the cage windows and inner race ball tracks.
  28.  
  29. Insert the remaining grease from the service kit into the seal.
  30.  
  31. Install the outer race retaining ring onto the axle shaft.
  32.  
  33. Position the retaining ring below the cage, toward the vise.
  34.  
  35. Install the balls through the cage windows to the inner race ball tracks.
  36.  
  37. Use the seal to keep the balls in position if necessary.
  38.  
  39. Install the outer race onto the axle shaft as follows:
    1. Be careful not to allow the grease in the outer race to leak out.
    2.  
    3. Align the outer race ball tracks to the balls.
    4.  
    5. Slide the outer race down over the balls.
    6.  

  40.  
  41. Position the wheel driveshaft horizontally in the bench vise. Engage the outer race retaining ring as follows:
    1. Slide the outer race toward the vise.
    2.  
    3. Insert the outer race retaining ring into the groove along the outer edge of the outer race.
    4.  
    5. Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track).
    6.  

  42.  
  43. Position the large diameter end of the seal onto the outer race.
  44.  
  45. Position the small seal retaining clamp onto the neck of the seal.
  46.  
  47. Position the seal and small retaining clamp to the axle shaft.
  48.  
  49. Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10 inch (2.5mm).
    NOTE
    The seal retaining clamp must not be over-tightened or under-tightened.

  50.  
  51. Crimp the small seal retaining clamp using tool J 42572. Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm). The clamping hold time must be no less than 2 seconds.

    Click image to see an enlarged view

    Fig. Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm)-inner joint



    Click image to see an enlarged view

    Fig. Measure the distance between the end of the seal and the end of the joint outer race and adjust the plunging motion of the joint to 8.90 inch within 0.16 inch (226mm within 4mm-inner joint



    Click image to see an enlarged view

    Fig. Measure the distance between the edge of the seal and the edge of the joint outer race last groove closing edge and adjust fit to 0.03 inch (0.8mm)-inner joint

  52.  
  53. Measure the distance between the end of the seal and the end of the joint outer race and adjust the plunging motion of the joint to 8.90 inch within 0.16 inch (226mm within 4mm).
  54.  
  55. Position the large seal retaining clamp onto the seal.
  56.  
  57. Position the seal and large retaining clamp to the joint outer race. Measure the distance between the edge of the seal and the edge of the joint outer race last groove closing edge and adjust fit to 0.03 inch (0.8mm).
    NOTE
    The seal must not be dimpled, stretched or out of shape in any way.

  58.  
  59. Inspect the seal for proper shape. If the seal is NOT shaped correctly, equalize the pressure in the seal and shape the seal properly by hand. Inspect the seal for damage. If the seal has been cut or punctured during assembly, you must discard and replace the seal.
    NOTE
    The seal retaining clamp must not be over-tightened or under-tightened.

  60.  
  61. Crimp the large seal retaining clamp using tool J 42572. Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm). The clamping hold time must be no less than 2 seconds.
  62.  
  63. Remove the wheel driveshaft from the bench vise.
  64.  
  65. Distribute the grease within the inner CV joint.
  66.  
  67. Plunge the joint back and forth four or five times.
  68.  
  69. Inspect the inner CV joint and wheel driveshaft for smooth operation as follows:
    1. Hold the wheel driveshaft vertically, with the outer joint at the bottom.
    2.  
    3. Rotate the wheel driveshaft four or five times in a circular motion.
    4.  

  70.  
  71. Install the axle shaft.
  72.  

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

    Axle shaft from the vehicle
     
    Large CV boot retaining clamp
     
    Small CV boot retaining clamp
     
    CV boot from the joint
     
    Outer joint from the axle shaft using a hammer and wood block

    Click image to see an enlarged view

    Fig. Separate the outer joint from the axle shaft using a hammer and wood block-outer joint



    Click image to see an enlarged view

    Fig. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage-outer joint

     
    Axle shaft retaining ring
     
    CV boot
     

  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.
    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.

    Click image to see an enlarged view

    Fig. Install the axle shaft retaining ring-outer joint



    Click image to see an enlarged view

    Fig. Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10 inch (2.5mm)



    Click image to see an enlarged view

    Fig. Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm)-outer joint



    Click image to see an enlarged view

    Fig. Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.3 inch (8mm)-outer joint



    Click image to see an enlarged view

    Fig. Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm)-outer joint

  8.  
  9. Install or connect the following:

    Small CV boot retaining ring
     
    CV boot on the halfshaft
     
    New retaining ring on the halfshaft
     
    Large ring clamp on the CV boot
     
    Outer joint onto the axle shaft
     

  10.  
  11. Compress the retaining ring using a small flat-bladed tool while pushing the outer joint onto the axle shaft.
  12.  
  13. Seat the outer joint on the shaft using a hammer and block of wood.
  14.  
  15. Install the remaining grease into the CV boot.
  16.  
  17. Position the CV boot and the small boot clamp.
  18.  
  19. Crimp the small boot clamp.
  20.  
  21. Position and crimp in place the large boot clamp.
  22.  
  23. Install the halfshaft in the vehicle.
  24.  

 
label.common.footer.alt.autozoneLogo