GM Lumina/Silhouette/Transport APVs 1990-1999 Repair Guide

Halfshafts

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REMOVAL AND INSTALLATION




WARNING
Care must be exercised to prevent Tri-Pot joints from being over-extended. When either end of the shaft is disconnected, over-extension of the joint could result in separation of the internal components and possible joint failure. Drive axle joint seal protectors should be used any time service is performed on or near the drive axles. Failure to observe this can result in interior joint or seal damage and possible joint failure.

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the tire and wheel assemblies.
  4.  
  5. Insert a drift or other suitable tool into the caliper and rotor to prevent the rotor from turning and remove the halfshaft retaining nut and washer. Remove and discard the cotter pin.
  6.  

See Figures 1, 2 and 3

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Fig. Fig. 1: Prevent the rotor from turning by inserting a drift through the caliper and into the rotor



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Fig. Fig. 2: Remove the hub nut (1) and the washer (2)



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Fig. Fig. 3: Pull the cotter pin and discard it

  1. Remove the brake caliper from the rotor and support it aside.
  2.  
  3. Remove the brake rotor from the hub.
  4.  
  5. Disconnect the lower ball joint pinch bolt.
  6.  
  7. Install a suitable drive axle seal protector. It may be necessary to modify the protector for installation.
  8.  

When servicing suspension components in the area in the area of the outer drive axle seal or when removing a drive axle, always install a suitable drive axle seal protector, after modifying it if necessary.

See Figure 4

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Fig. Fig. 4: It is necessary to install a modified drive axle seal protector to prevent the seal from being damaged

  1. Remove the ball joint from the steering knuckle.
  2.  
  3. Remove the halfshafts from the hub and bearing assembly using a suitable puller
  4.  

See Figure 5

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Fig. Fig. 5: Pull the hub, bearing, and knuckle assembly away from the halfshaft

  1. Remove the halfshafts from the spindle, using a suitable spindle removal tool.
  2.  
  3. Remove the halfshafts from the transaxle using a suitable tool with a slide hammer attachment.
  4.  

See Figures 6 through 11

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Fig. Fig. 6: Although you can use a large pry tool to separate the inner CV-joint from the transaxle case, it is better to use the proper tool and slide hammer



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Fig. Fig. 7: Carefully remove the halfshaft from the vehicle



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Fig. Fig. 8: The end of the halfshaft is grooved and has a retaining circlip



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Fig. Fig. 9: While the halfshaft is removed, be sure not to get any dirt or other debris in the transaxle case



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Fig. Fig. 10: Exploded view of the drive axle removal



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Fig. Fig. 11: The drive axle MUST be handled properly to avoid damage

To install:
  1. Install the a suitable tear away axle seal protector tool, to the right side of the transaxle in a position so it can be pulled out after the drive axle is installed (approximately between 5 and 7 o'clock position).
  2.  
  3. Install the a suitable axle seal protector to the drive axle.
  4.  
  5. Install the axle into transaxle.
  6.  
  7. Remove and discard the tear away axle seal protector tool. Make sure that there are no pieces of the tool left inside of the transaxle, if so, repeat the steps necessary to remove the drive axle and correct the condition.
  8.  
  9. Install the axle shaft in the hub.
  10.  
  11. Install the lower control arm ball joint to the steering knuckle.
  12.  
  13. Install the lower ball joint pinch bolt, then tighten the ball joint pinch bolt nut to 33 lb. ft. (45 Nm).
  14.  
  15. Install the brake rotor and brake caliper.
  16.  
  17. Install a drift or other suitable tool to hold the caliper and rotor stationary, and prevent them from rotating.
  18.  
  19. Install the drive axle washer and a new nut. Tighten the nut to 185 ft. lbs. (260 Nm).
  20.  
  21. Remove the drift or other suitable tool from the caliper and rotor.
  22.  
  23. Remove the modified axle seal protector tool.
  24.  
  25. Seat the drive axle into the transaxle by placing a suitable tool into the groove on the joint housing and tapping it until properly seated.
  26.  
  27. Verify that the drive axle is seated into the transaxle by grasping on the housing and pulling outboard.
  28.  

Do not grasp and pull on the axle shaft.

  1. Install the tire and wheel assembly.
  2.  
  3. Lower the vehicle.
  4.  

OVERHAUL



Outer CV-Joint and Seal
  1. Remove the halfshaft from the vehicle and mount in a suitable vise.
  2.  

See Figures 12 and 13

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Fig. Fig. 12: Check the CV-boot for wear



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Fig. Fig. 13: Clean the CV-joint housing prior to removing the boot

  1. Remove the large seal retaining clamp from the CV-joint with side cutters. Discard the clamp.
  2.  
  3. Remove the small seal retaining clamp with side cutters or, for swage ring removal, use a hand grinder to cut through the ring (being careful not to damage the halfshaft).
  4.  
  5. Separate the joint seal from the CV-joint race at the large diameter end and slide the seal away from the joint along the axle shaft.
  6.  
  7. Wipe off the grease from the face of the CV inner race.
  8.  
  9. Spread the ears on the race retaining ring with a suitable pair of snapring pliers and remove the CV-joint from the axle shaft.
  10.  

See Figure 14

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Fig. Fig. 14: Use a pair of snapring pliers to spread the ears on the race retaining ring

  1. Remove the joint seal from the axle shaft.
  2.  
  3. Use a brass drift and hammer to gently tap on the CV-joint cage until it is tilted enough to remove the first ball.
  4.  

See Figure 15

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Fig. Fig. 15: Gently tap on the cage with a brass drift and hammer, until it is tilted enough to remove the first ball

  1. Tilt the cage in the opposite direction and remove the opposing ball.
  2.  
  3. Repeat until all the ball are removed. There are usually 6 balls.
  4.  
  5. Position cage and inner race 90° to centerline of the outer race, and align cage windows with the lands of the outer race.
  6.  

See Figure 16

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Fig. Fig. 16: Place the cage and inner race 90° to centerline of the outer race, and align the cage windows with the lands of the outer race

  1. Remove the cage and inner race from the outer race.
  2.  
  3. Rotate the inner race 90° to centerline of the cage so that the lands of the inner race are aligned with the windows of the cage.
  4.  

See Figure 17

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Fig. Fig. 17: Rotate the inner race 90° to centerline of the cage, so that the lands of the inner race are aligned with the windows of the cage

  1. Pivot the inner race into cage window and remove the inner race.
  2.  
  3. Clean the inner and outer race assemblies, cage and balls thoroughly with a suitable solvent. All traces of old grease and contaminants must be removed. Thoroughly dry all parts.
  4.  

To install:
  1. If equipped, install a new swage ring on the neck of the seal. Do not swage.
  2.  
  3. Slide the seal onto the axle shaft on position the neck of the seal in the seal groove on the axle shaft.
  4.  
  5. For the swage ring, mount a suitable swage clamp tool in a vise and proceed as follows:
    1. Position the outboard end of the halfshaft in the tool.
    2.  
    3. Align the top of the seal neck on the bottom die using the indicator line.
    4.  
    5. Place the top half of the tool on the lower half of the tool.
    6.  
    7. Make sure there are no pinch points on the seal before continuing. Any pinching could damage the seal.
    8.  
    9. Install the bolts and tighten by hand until snug.
    10.  
    11. Make sure that the seal, housing and swage ring all stay in alignment. Continue to tighten each bolt 180°, alternating until both sides are bottomed.
    12.  

  6.  

See Figure 18

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Fig. Fig. 18: Mount the swage clamp tool and axle in a suitable vise

  1. Put a light coat of grease from the service kit on the ball grooves of the inner race and outer race.
  2.  
  3. Hold the inner race 90° to centerline of the cage with the lands of the inner race aligned with the windows of the cage and insert the inner race into the cage.
  4.  
  5. Hold the cage and inner race 90° to centerline of the outer race and align the cage windows with the lands of the outer race.
  6.  
  7. Install the cage and inner race into the outer race.
  8.  

Make sure that the retaining ring side of the inner race faces the axle shaft.

  1. Insert the first ball, then tilt the cage in the opposite direction to install the opposing ball. Repeat this process until the remaining balls are installed.
  2.  
  3. Place about half the grease from the service kit inside the seal and pack the CV-joint with the remaining grease.
  4.  
  5. Push the CV joint onto the axle shaft until the retaining ring is seated in the groove on the axle shaft.
  6.  
  7. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of the CV joint race and locate the seal lip in the groove on the race.
  8.  

See Figure 19

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Fig. Fig. 19: Slide the large end of the seal over the outside of the CV-joint race and seat the seal lip in the groove on the race


WARNING
The seal must not be dimpled, stretched or out of shape in any way. IF the seal is NOT shaped correctly, equalize pressure in seal and shape seal properly by hand or replace.

  1. Crimp the retaining clamp to 130 ft. lbs. (176 Nm).
  2.  

See Figure 20

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Fig. Fig. 20: Use a breaker bar and torque wrench to crimp the seal retaining clamp to the proper specifications

  1. Install the halfshaft into the vehicle.
  2.  

Inner Tri-Pot Joint and Seal

See Figures 21 and 22

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Fig. Fig. 21: Exploded view of the halfshaft assembly-1992 vehicle shown



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Fig. Fig. 22: Exploded view of the halfshaft assembly-1998 vehicle shown

See Figures 23 and 24

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Fig. Fig. 23: Mount the swage clamp tool and axle in a suitable vise



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Fig. Fig. 24: Use a breaker bar and torque wrench to crimp the seal retaining clamp to the proper specifications

  1. Remove the halfshaft from the vehicle and mount in a suitable vise.
  2.  
  3. If equipped, remove the swage ring from the axle shaft using a hand grinder to cut through the ring (being careful not to damage the halfshaft).
  4.  
  5. Remove the large retaining clamp from tri-pot joint with side cutter, and discard.
  6.  


WARNING
Do not cut through the seal and damage the sealing surface of tri-pot housing and trilobal tri-pot bushing.

  1. If necessary, remove the small seal retaining clamp using side cutters.
  2.  
  3. Separate the seal from the trilobal tri-pot bushing at large diameter and slide seal away from the joint.
  4.  
  5. Remove the tri-pot housing from the spider and shaft. Remove the trilobal tri-pot bushing from the housing.
  6.  
  7. Spread the spacer ring with a pair of snapring pliers and slide space ring and tri-pot spider back on axle shaft.
  8.  

See Figures 25 and 26

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Fig. Fig. 25: View of the spider assembly



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Fig. Fig. 26: Use a pair of snapring pliers to spread the ears of the spacer ring

  1. Remove the shaft retaining ring from the groove on the axle shaft, then slide the spider from the shaft. Clean the tri-pot balls, needle rollers and housing thoroughly with suitable solvent. All traces of old grease and contaminants must be removed. Thoroughly dry all parts.
  2.  
  3. Remove the trilobal tripot bushing from the tripot housing.
  4.  
  5. Remove the spacer ring and seal from the axle shaft.
  6.  
  7. Inspect the joint balls and needle rollers for damage or wear. Handle with care, and don't reuse them if there is any sign of damage.
  8.  

To install:
  1. Install a new small seal retaining clamp, or swage, as applicable. Do NOT crimp/swage.
  2.  
  3. Slide the seal onto the axle shaft and position neck of seal in groove on the axle shaft.
  4.  

See Figure 27

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Fig. Fig. 27: Seal retaining clamp installation

  1. For the swage ring, mount the swage clamp tool, J 41048 or equivalent, in a vise and proceed as follows:
    1. Position the outboard end of the halfshaft in the tool.
    2.  
    3. Align the top of the seal neck on the bottom die using the indicator line.
    4.  
    5. Place the top half of the tool on the lower half of the tool.
    6.  
    7. Make sure there are no pinch points on the seal before continuing. Any pinching could damage the seal.
    8.  
    9. Install the bolts and tighten by hand until snug.
    10.  
    11. Make sure that the seal, housing and swage ring all stay in alignment. Continue to tighten each bolt 180°, alternating until both sides are bottomed.
    12.  

  2.  
  3. If equipped, crimp the seal using a breaker bar and torque wrench to 100 ft. lbs. (136 Nm).
  4.  
  5. Install the spacer ring onto the axle shaft and beyond the second groove.
  6.  
  7. Slide the tri-pot spider toward the spacer ring as far as it will go on the shaft. Make sure the counterbored face of the tri-pot spider faces the end of the axle shaft.
  8.  
  9. Use snapring pliers to install the shaft retaining ring in the groove of the axle shaft.
  10.  
  11. Slide the tri-pot spider towards the end of the axle shaft and reseat the spacer ring in the groove on shaft.
  12.  
  13. Place about half the grease provided with the repair kit into the seal and use the remainder to repack the tri-pot housing.
  14.  
  15. Install the trilobal tri-pot bushing to the housing. Make sure the bushing is flush with the face of the housing.
  16.  
  17. Position the new large clamp on the seal.
  18.  
  19. Slide tri-pot housing over the tri-pot spider on axle shaft and remove the slotted sheet metal plate.
  20.  
  21. Slide large diameter end of seal with large clamp in place, over the outside of the trilobal bushing, and locate the lip of seal in the bushing groove.
  22.  
  23. Position the tri-pot at the proper vehicle dimension, 4.9 inches (125mm).
  24.  

See Figure 28

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Fig. Fig. 28: Measuring tri-pot seal installation


WARNING
The seal must not be dimpled, stretched or out of shape in any way. If the seal is NOT shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) into the between the large seal opening and trilobal tri-pot bushing to equalize pressure. Shape the seal properly by hand and remove the tool.

  1. Use a breaker bar and torque wrench to crimp retaining clamp to 130 ft. lbs. (176 Nm).
  2.  
  3. Make certain the seal, housing and large clamp all remain in alignment while crimping.
  4.  
  5. Install the halfshaft in the vehicle.
  6.  

See Figure 29

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Fig. Fig. 29: Torque Specifications

 
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