Corvette 2005-2008

Halfshafts

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CV-Joints



Overhaul

CAUTION
When servicing the wheel drive shaft(s), place reference marks on all components to ensure that all components are reassembled in the correct position. If the components are not reassembled in the correct position, premature wear of the joint and/or excessive driveline vibrations may occur.



Click image to see an enlarged view

Fig. Halfshaft exploded view

Inner Joint
Non Z06/Z51
  1. Remove the axle shaft from the vehicle.
  2.  
  3. Wrap a shop towel around the axle shaft.
  4.  
  5. Place the wheel drive shaft horizontally in a bench vise.
  6.  
  7. Remove the large seal retaining clamp from the CV joint seal (boot).
  8.  
  9. Remove the small seal retaining clamp from the joint seal.
  10.  
  11. Separate the seal from the joint outer race at the large diameter end.
  12.  
  13. Position the seal behind the joint face.
  14.  
  15. Position the wheel drive shaft vertically in the bench vise so the inner joint is up.
  16.  
  17. Disengage the outer race retaining ring.
    1. Slide the joint outer race down toward the vise.
    2.  
    3. Insert a small flat-bladed screwdriver between the retaining ring and the outer race.
    4.  
    5. Remove the retaining ring from the outer race.
    6.  
    7. 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.

    8.  

  18.  
  19. Remove the outer race from the axle shaft.
  20.  
  21. Remove all balls.
  22.  
  23. Position the wheel drive shaft horizontally in the bench vise.
  24.  
  25. Remove the outer race retaining ring from the axle shaft.
  26.  
  27. Remove the snap ring from the axle shaft.
  28.  
  29. Reposition the cage along the axle shaft away from the inner race.
  30.  
  31. Wipe the grease from the inner race.
  32.  
  33. Remove the inner race from the axle shaft using a 3 jaw puller.

    Click image to see an enlarged view

    Fig. Remove the inner race from the axle shaft using a 3 jaw puller

  34.  
  35. Remove the cage from the axle shaft.
  36.  
  37. Remove the seal from the axle shaft.
  38.  
  39. Remove the axle shaft from the bench vise.
  40.  

To install:


NOTE
All traces of old grease and any contaminates must be removed.

  1. Clean all part surfaces thoroughly with clean solvent:
    1. Thoroughly air dry all the parts.
    2.  

  2.  
  3. Wrap a shop towel around the axle shaft.
  4.  
  5. Place the wheel drive shaft horizontally in a bench vise.
  6.  
  7. Install a new small seal retaining clamp onto the axle shaft.
  8.  
  9. Install the seal onto the axle shaft.
  10.  
  11. Install the cage onto the axle shaft so the smaller diameter end faces the vise.
  12.  
  13. Install the inner race onto the axle shaft.
    1. Engage the inner race splines onto the axle shaft splines.
      NOTE
      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.
    6.  

  14.  
  15. Reposition the wood block along the face of the inner race to avoid the axle shaft.
  16.  
  17. 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.
    1. Inspect to be sure that the axle shaft snap ring groove is exposed.
    2.  

  18.  
  19. Install the snap ring to the axle shaft.
  20.  
  21. Position the cage so the cage lands align with the inner race ball tracks.
  22.  
  23. Install the cage onto the inner race.
  24.  
  25. Position the cage windows to align with the inner race ball tracks.
  26.  
  27. Insert approximately 60 percent of the grease from the service kit into the outer race.
  28.  
  29. Position the wheel drive shaft vertically in the bench vise so the inner joint end is up.
  30.  
  31. Apply a small amount of the grease from the service kit to the cage windows and inner race ball tracks.
  32.  
  33. Insert the remaining grease from the service kit into the seal.
  34.  
  35. Install the outer race retaining ring onto the axle shaft.
  36.  
  37. Position the retaining ring below the cage toward the vise.
  38.  
  39. Install the balls through the cage windows to the inner race ball tracks.
    NOTE
    Use the seal to keep the balls in position if necessary.



    Click image to see an enlarged view

    Fig. Install the balls through the cage windows to the inner race ball tracks

  40.  
  41. Install the outer race onto the axle shaft.
    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.  

  42.  
  43. Position the axle shaft horizontally in the bench vise.
  44.  
  45. Engage the outer race retaining ring.
    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.  

  46.  
  47. Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track).
  48.  
  49. Position the large diameter end of the seal onto the outer race.
  50.  
  51. Position the small seal retaining clamp (3) onto the neck of the seal (4).
    1. Position the seal and small retaining clamp to the axle shaft (2) as shown.
    2.  
    3. Measure the distance (1) between the edge of the seal and the edge of the last axle shaft groove closing edge; adjust fit to specification 0.01inch (2.5 mm).
      NOTE
      Seal Clamp must be securely clamped in the seal groove and buckle securely fastened so as not to come loose and ride on the seal.



      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

    4.  
    5. Using the J-42572 , crimp the small seal retaining clamp, tighten the small seal retaining clamp until the gap width (a) between 0.039 and 0.157 in (1 and 4 mm).
      NOTE
      The seal retaining clamp must not be over-tightened or under-tightened.



      Click image to see an enlarged view

      Fig. Tighten the small seal retaining clamp



      Click image to see an enlarged view

      Fig. Measure the distance (1) between the end of the seal and the end of the joint outer race

    6.  

  52.  
  53. Position the seal and large retaining clamp to the joint outer race and crimp accordingly.
    1. Measure the distance (1) 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 (.8mm).
      NOTE
      Inspect the seal for proper shape.



      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 (.8mm)



      The seal must not be dimpled, stretched or out of shape in any way.
       
      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.
       

    2.  

  54.  
  55. Install the halfshaft in the vehicle.
  56.  

Z06/Z51
  1. Install wheel drive shaft bar in a soft jawed vise and clamp securely.
  2.  
  3. Using side cutters, remove and discard the small seal clamp.
  4.  
  5. Using a flat-bladed tool, remove large seal retaining clamp and discard the clamp.
  6.  
  7. Remove the large seal from the tripod housing and slide the seal away from the tripod housing.
  8.  
  9. Remove the excess grease from the face of the tripod spider and the inside of the tripod housing.
    NOTE
    The rollers may fall off the spider assembly when the tripod joint is removed from the housing.

  10.  
  11. Remove the spider assembly and the tripod housing from the axle shaft.
  12.  
  13. Remove the rollers from the spider assembly.
  14.  
  15. Remove the snap ring from the axle shaft.

    Click image to see an enlarged view

    Fig. Remove the snap ring from the axle shaft

  16.  
  17. Remove the seal from the axle shaft.
  18.  

To install:

  1. Thoroughly clean all parts with a suitable solvent, removing all traces of grease and contaminants.
    1. Dry all parts with compressed air.
    2.  
    3. Inspect the tripod joint components for unusual wear, cracks, and other damage. If any of the tripod joint components are damaged, replace the wheel drive shaft
    4.  

  2.  
  3. Position the small seal retaining clamp (3) onto the neck of the seal (4).
  4.  
  5. Position the seal and the small retaining clamp to the axle shaft (2) as shown.
    NOTE
    The Seal clamp must be securely clamped in the seal groove and buckle securely fastened so as not to come loosen and ride the seal.



    Click image to see an enlarged view

    Fig. Position the seal and the small retaining clamp to the axle shaft

  6.  
  7. Install the small seal clamp to the seal. Do not crimp the clamp.
  8.  
  9. Using the J-35910 , crimp the small seal retaining clamp until the measured gap width is between 0.038 and 0.157 in (1 and 4 mm).
  10.  
  11. Install the tripod spider assembly to the wheel drive shaft bar, until seated against shoulder.
  12.  
  13. Using the J-8059 , install the retaining ring in the groove of the axle shaft.
  14.  
  15. Place approximately half of the grease in the kit to the seal and place the remainder in the tripod housing.
  16.  
  17. Install the large clamp over the large diameter of the seal.
  18.  
  19. Install the rollers on the spider assembly.
  20.  
  21. Install the tripod housing to the tripod spider assembly on the axle shaft bar.
  22.  
  23. Slide the large diameter of the seal over the outside of the tripod housing and position the lip of the seal in the housing groove.
    NOTE
    Ensure that the seal is properly seated in the groove of the tripod housing.

  24.  
  25. Position the large retaining clamp around the seal in the groove.
  26.  
  27. Using the J-35910 , crimp the large retaining clamp until the measured gap width is between 0.038 and 0.157 inch (1 and 4 mm).
  28.  
  29. Rotate the housing in a circular motion to distribute the grease in the tripod joint.
  30.  
  31. Install the halfshaft in the vehicle.
  32.  

Outer Joint
  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 axle shaft horizontally in a bench vise.
  8.  
  9. Remove the large seal retaining clamp from the CV joint seal (boot).
  10.  
  11. Remove the small seal retaining clamp from the joint seal. Use a side cutter or other suitable tool and discard the clamp.
  12.  
  13. Separate the seal from the joint outer race at the large diameter end.
  14.  
  15. Position the seal behind the joint face.
  16.  
  17. Wipe the grease from the face of the joint inner race, cage, balls, etc.
  18.  
  19. Remove the outer joint from the axle shaft.
    1. Have an assistant hold the joint housing.
    2.  
    3. Position a wood block between the seal and the joint along the joint face.
    4.  
    5. Strike the wood block with a hammer to compress the axle shaft retaining clip.
    6.  
    7. Continue to strike the wood block to remove the outer joint from the axle shaft.
    8.  

  20.  
  21. Remove the axle shaft retaining ring from the axle shaft.
  22.  
  23. Remove the seal from the axle shaft.
  24.  
  25. Remove the axle shaft from the vise.
  26.  
  27. Wrap a shop towel around the joint outer race splined shaft to protect from damage.
  28.  
  29. Place the outer race vertically in a bench vise.
  30.  
  31. Make a ball accessible for removal.
    1. Tap gently on the joint cage, using a brass drift and a hammer, in order to drive a ball toward the bottom of its track. The opposing ball will be made accessible for removal.
    2.  
    3. Remove the exposed ball.
    4.  
    5. Position the cage and inner race so they are level.
    6.  
    7. Repeat these steps in the removal sequence until you remove all six balls.

      Click image to see an enlarged view

      Fig. Remove the exposed ball

    8.  

  32.  
  33. Rotate the cage and inner race 90 degrees to the outer race and remove.

    Click image to see an enlarged view

    Fig. Rotate the cage and inner race 90 degrees to the outer race and remove

  34.  
  35. Position the cage and inner race so that the larger radius corners of the cage windows are up.
  36.  
  37. Rotate the inner race 90 degrees and remove.
  38.  

To install:


NOTE
All traces of old grease and any contaminates must be removed.

  1. Clean all part surfaces thoroughly with clean solvent:
    1. Thoroughly air dry all the parts.
    2.  

  2.  
  3. Position the cage so the larger radius corners of the cage windows are up.
  4.  
  5. Position the inner race 90 degrees to the cage, insert and rotate into position.
    1. Rotate the inner race within the cage so that the grooved surface of the inner race is facing up.
    2.  
    3. Align the inner race ball tracks with the cage windows.
    4.  

  6.  
  7. Wrap a shop towel around the joint outer race splined shaft.
  8.  
  9. Place the outer race vertically in a bench vise.
  10.  
  11. Position the cage and inner race 90 degrees to the outer race.
    1. Align two cage windows.
    2.  
    3. Insert the cage and inner race into the outer race.
      NOTE
      The larger radius corners of the cage windows should be positioned up and the grooved surface of the inner race should be visible.

    4.  
    5. Position the cage and inner race so they are level.
    6.  

  12.  
  13. Position a cage window and inner race ball track for ball installation.
    1. Press down on the cage following one of the outer race ball tracks. The opposing cage window and inner race ball track will be accessible for ball installation.
    2.  
    3. After you install the first ball, you will need to use a brass drift and a hammer to tap gently on the cage, in order to drive the cage and inner race down completely.
      NOTE
      No gap should exist between the ball and the inner race ball track.

    4.  
    5. Insert a ball through the cage window onto the inner race ball track.
    6.  
    7. Tap the ball lightly with a plastic tipped hammer.
    8.  
    9. Position the cage and inner race so they are level.
    10.  
    11. Repeat these steps in the installation sequence until you install all six balls.
    12.  

  14.  
  15. Insert approximately 60 percent of the grease from the service kit into the outer joint.
    1. Spread the grease onto the ball tracks, the balls, the cage and the inner race.
    2.  
    3. Spread the remainder of the grease into the bottom of the outer race.
    4.  

  16.  
  17. Remove the outer joint from the bench vise.
  18.  
  19. Wrap a shop towel around the axle shaft.
  20.  
  21. Place the axle shaft horizontally in a bench vise.
  22.  
  23. Install a new small seal retaining clamp onto the axle shaft.
  24.  
  25. Install the seal onto the axle shaft.
  26.  
  27. Install the axle shaft retaining ring to the axle shaft.
  28.  
  29. Position the outer joint horizontally.
  30.  
  31. Engage the inner race splines onto the axle shaft splines.
  32.  
  33. Compress the axle shaft retaining ring.
    1. Press one end of the retaining ring, using a flat bladed screwdriver or equivalent tool, into the axle shaft groove while firmly pressing the outer joint onto the axle shaft.
    2.  
    3. Continue to work around the retaining ring until it is compressed.
    4.  

  34.  
  35. Install the outer joint to the axle shaft.
    NOTE
    The axle shaft and inner race must be fully seated to each other.

    1. Position a wood block squarely over the end of the outer joint threaded shaft.
    2.  
    3. Use a hammer to drive the outer joint onto the shaft.
    4.  
    5. Continue to drive the outer joint until you feel the outer joint seat fully onto the axle shaft.
    6.  
    7. Inspect to be sure that the axle shaft and the inner race stepped surfaces are fully seated to each other.

      Click image to see an enlarged view

      Fig. Install the outer joint to the axle shaft

    8.  

  36.  
  37. Insert the remaining grease from the service kit into the seal.
  38.  
  39. Position the small seal retaining clamp onto the neck of the seal and crimp accordingly.
  40.  
  41. 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. 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)

    1. 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 (1) 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.
      NOTE
      The seal retaining clamp must not be over-tightened or under-tightened.



      Click image to see an enlarged view

      Fig. Crimp the small seal retaining clamp

    2.  

  42.  
  43. Position the seal and large retaining clamp to the joint outer race and crimp accordingly.
    1. 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 (.8mm).
      NOTE
      Inspect the seal for proper shape.



      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 (.8mm)



      The seal must not be dimpled, stretched or out of shape in any way.
       
      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.
       

    2.  

  44.  
  45. Install the halfshaft in the vehicle.
  46.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Apply the parking brake.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Be sure to support the halfshaft until it is removed. Do not let it hang by the CV-joint.



    Wheel
     
    Axle nut
     
    Rear transverse spring
     
    Outer tie rod end from the knuckle
     
    Antilock Brake System (ABS) Wheel Speed Sensor (WSS) electrical connector
     
    Park brake cable from the lever and bracket
     

  6.  
  7. Attach a puller on the wheel studs and start to push the axle shaft into the hub assembly. This will provide clearance for the ball joint to be separated from the knuckle assembly.
  8.  
  9. Remove or disconnect the following:

    Ball joint from the knuckle
     
    Axle shaft from the hub
     
    Using a slide hammer or another suitable puller, remove the halfshaft assembly from the differential by inserting the puller between the CV-joint and differential and separating them apart.

    Click image to see an enlarged view

    Fig. Insert a large drift through the cooling fins to keep the hub assembly from turning while removing the retaining nut

     

  10.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the halfshaft mounting

  1. Install or connect the following:

    Halfshaft on the differential output shaft. Use light force to be sure it is fully seated
     
    Halfshaft through the hub assembly but do not install completely. This will provide clearance for installing the ball joint
     
    Ball joint to the knuckle and torque the nut to 41 ft. lbs. (55 Nm)
     
    Halfshaft through the hub assembly completely
     
    Park brake cable to the bracket and the lever
     
    WSS electrical connector
     
    Tie rod end to the knuckle and torque the nut to 15 ft. lbs. (20 Nm) plus an additional 160 degrees
     
    Rear transverse spring and torque the bolts to 46 ft. lbs. (62 Nm)
     
    Halfshaft retaining nut and torque the nut to 118 ft. lbs. (160 Nm)
     
    Wheel
     

  2.  

 
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