G6 2005-2007

Halfshafts

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CV-Joints



Inspection
  1. Raise and support the vehicle safely.
  2.  
  3. Spin drive axles by hand at the wheel.
  4.  
  5. Check for loose clamps, cracks, or open boots.
  6.  
  7. Check inner and outer boots.
  8.  
  9. Look for signs of grease leaking from axle boots.
  10.  
  11. Repair as needed.
  12.  

Overhaul
Inner Joint
  1. Disassemble the joint as follows:
  2.  
  3. Disconnect the swage ring from the halfshaft bar using a hand grinder to cut through the ring, taking care not to damage the halfshaft bar.
  4.  
  5. Remove the large seal retaining clamp from the tripot joint with side cutters. Discard the large seal retaining clamp.
  6.  
  7. Separate the inboard seal from the trilobal tripot bushing at the large diameter.
  8.  
  9. Slide the seal away from the joint along the halfshaft bar.
  10.  
  11. Remove the housing from the tripot joint spider and the halfshaft bar.
  12.  
  13. Spread the spacer ring.
  14.  
  15. Remove the spacer ring, spider assembly, spacer ring and tripot boot. Discard the boot and rings.
  16.  
  17. Clean the halfshaft bar Use a wire brush in order to remove any rust in the boot mounting area (grooves).
  18.  
  19. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit.
  20.  

To install:

  1. Place the new small swage ring or eared clamp onto the small end of the joint seal. Slide the joint seal and the small swage ring or eared clamp onto the halfshaft bar.
  2.  
  3. Position the small end of the joint seal into the joint seal groove on the halfshaft bar.
  4.  
  5. For swage ring installation, mount Drive Axle Swage Ring Clamp J-41048 in a vise.
  6.  
  7. Position the inboard end of the halfshaft assembly in the tool.
  8.  
  9. Align the top of the seal neck on the bottom die using the indicator.
  10.  
  11. Place the top half of the tool on the lower half.
  12.  
  13. Before proceeding, ensure there are no pinch points on the halfshaft inboard seal. This could cause damage to the halfshaft inboard seal.
  14.  
  15. Insert the bolts  and tighten the bolts by hand until snug.
  16.  
  17. Align the halfshaft inboard seal, the halfshaft bar and the swage ring.
  18.  
  19. Tighten each bolt of the tool 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
  20.  
  21. For eared clamp installation, mount the halfshaft into a vise.
  22.  
  23. Slide the tripot seal to the corresponding groove on the halfshaft bar.
  24.  
  25. Crimp the eared clamp using clamping pliers, a torque wrench, and a breaker bar.
  26.  
  27. If equipped, install the spacer ring into the groove of the halfshaft bar.
  28.  
  29. Slide the tripot joint spider assembly as far as it will go on the halfshaft bar.
  30.  
  31. Install the spacer ring into the groove of the halfshaft bar.
  32.  
  33. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the remainder of the grease to repack the housing.
  34.  
  35. Ensure the trilobal tripot bushing is flush with the face of the housing.
  36.  
  37. Install the trilobal tripot bushing to the housing.
  38.  
  39. Position the larger new seal retaining clamp on the halfshaft inboard seal.
  40.  
  41. Slide the housing over the tripot joint spider assembly on the halfshaft bar.
  42.  
  43. Slide the large diameter of the halfshaft inboard seal, with larger clamp in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
  44.  
  45. Align the halfshaft inboard seal, tripot housing and large seal retaining clamp.
  46.  
  47. Crimp the seal retaining clamp with to 130 ft. lbs. (176 Nm). Add the breaker bar and the torque wrench if needed.
  48.  
  49. Check the gap dimension on the clamp ear. If the gap dimension is larger than 0.102 inch (2.6mm), continue tightening until the dimension is reached.
  50.  
  51. Fully stroke the joint several times to disperse the grease.
  52.  

Outer Joint
  1. Disassemble the joint as follows:
  2.  
  3. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp.
  4.  
  5. Use a hand grinder to cut through the swage ring in order to remove the swage ring.
  6.  
  7. Separate the halfshaft outboard seal from CV joint outer race at the large diameter.
  8.  
  9. Slide the seal away from joint along the halfshaft bar.
  10.  
  11. Wipe the grease from the face of the CV joint inner race.
  12.  
  13. Spread the ears on the race retaining ring with snap ring pliers.
  14.  
  15. Remove the CV joint assembly from the halfshaft bar.
  16.  
  17. Remove and discard the halfshaft outboard seal.
  18.  
  19. Place a brass drift against the CV joint cage.
  20.  
  21. Tap gently on the brass drift with a hammer in order to tilt the cage.
  22.  
  23. Remove the first chrome alloy ball when the CV joint cage tilts.
  24.  
  25. Tilt the CV joint cage in the opposite direction to remove the opposing chrome alloy ball.
  26.  
  27. Repeat this process to remove all 6  of the balls.
  28.  
  29. Pivot the CV joint cage and the inner race 90 degrees to the centerline of the outer race. At the same time, align the cage windows  with the lands of the outer race.
  30.  
  31. Lift out the cage and the inner race.
  32.  
  33. Remove the inner race from the cage by rotating the inner race upward.
  34.  
  35. Clean all parts with solvent and replace any damaged parts.
  36.  

To install:

  1. Assemble the joint as follows:
  2.  
  3. Install the new swage ring or eared clamp on the neck of the outboard seal. Do not swage or crimp.
  4.  
  5. Slide the outboard seal onto the halfshaft bar and position the neck of the outboard seal in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove.
  6.  
  7. For swage ring installation, position the outboard end of the halfshaft assembly Drive Axle Swage Ring Clamp J-41048.
  8.  
  9. Align the swage ring.
  10.  
  11. Place the top half of the clamp tool onto the lower half.
  12.  
  13. Align the outboard seal, halfshaft bar and swage ring.
  14.  
  15. Insert the bolts and tighten by hand until snug.
  16.  
  17. Tighten each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
  18.  
  19. Loosen the bolts and separate the dies.
  20.  
  21. Check swaged ring for any lip deformities. If present, place the ring back into the tool making sure the ring covers the whole swaging area. If necessary, re-swage the ring.
  22.  
  23. For eared clamp installation, mount the halfshaft into a soft-jawed vise.
  24.  
  25. Install the new eared clamp on the neck of the seal. Do not crimp.
  26.  
  27. Slide the seal onto the halfshaft bar and position the neck of the seal in the seal groove on the bar.
  28.  
  29. Crimp the eared clamp using seal clamping pliers, a breaker bar, and a torque wrench.
  30.  
  31. Tighten the eared clamp to 100 ft. lbs. (136 Nm).
  32.  
  33. Check the gap dimension and continue tightening until the gap is 0,085 inch (2.15mm).
  34.  
  35. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race.
  36.  
  37. \Hold the inner race 90 degrees to centerline of cage with the lands of the inner race aligned with the windows of the cage and insert the inner race into the cage.
  38.  
  39. Hold the cage and the inner race 90 degrees to centerline of the outer race and align the cage windows with the lands of the outer race.
  40.  
  41. Ensure that the retaining ring side of the inner race faces the halfshaft bar.
  42.  
  43. Place the cage and the inner race into the outer race.
  44.  
  45. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball.
  46.  
  47. Repeat this process until all 6 balls are in place.
  48.  
  49. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.
  50.  
  51. Push the CV joint onto the halfshaft bar until the retaining ring is seated in the groove on the halfshaft bar.
  52.  
  53. Slide large diameter of the outboard seal with the large seal retaining clamp in place over the outside of the CV joint outer race and locate the seal lip in the groove on the CV joint outer race.
  54.  
  55. Crimp the seal retaining clamp to 130 ft. lbs. (174 Nm).
  56.  
  57. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is 0.074 inch (1.9mm).
  58.  

Removal & Installation



  1. Raise and support the vehicle safely.
  2.  
  3. Remove the front wheel.
  4.  
  5. Remove the halfshaft nut.
  6.  
  7. Disconnect the outer tie rod assembly from the steering knuckle.
  8.  
  9. Separate the ball joint from the steering knuckle.
  10.  
  11. Separate the front wheel drive axle from the drive shaft bearing using a slide hammer and appropriate puller. The nut can be partially re-installed to protect the threads.
  12.  
  13. Remove the halfshaft from the transaxle.
  14.  

To install:

  1. Install the halfshaft into the transaxle.
  2.  
  3. Verify that the front wheel drive shaft retaining ring is properly seated by grasping the inner housing and pull the inner housing outward. Do not pull on the front wheel drive axle shaft.
  4.  
  5. The front wheel drive axle will remain in place when the front wheel drive shaft retaining ring is properly seated.
  6.  
  7. Install the front wheel drive shaft into the front wheel bearing.
  8.  
  9. Connect the ball joint to the steering knuckle.
  10.  
  11. Connect the outer tie rod assembly to the steering knuckle.
  12.  
  13. Install a new wheel drive shaft nut. Insert a drift or a flat-bladed tool into the caliper and the rotor to prevent the rotor from turning. Tighten the nut to 159 ft. lbs. (215 Nm).
  14.  
  15. Install the wheel and tire.
  16.  
  17. Lower the vehicle.
  18.  
  19. Inspect the transaxle fluid level.
  20.  
  21. Inspect the wheel alignment.
  22.  

 
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