Malibu 2001-2005

CV-Joints

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Overhaul



Inner CV-Joint & Boot
  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 and discard it
     
    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 beyond the second 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 of the grease provided into the boot
     
    The remaining 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. Using a Crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. lbs. (176 Nm).
  8.  
  9. Check the clamp gap dimension; if it is not 0.085 in. (2.16mm), continue tightening the clamp until it is.
  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
     
    Outer race from the halfshaft by spreading the outer race-to-halfshaft retaining ring
     
    Retaining ring from the halfshaft
     
    CV-joint boot from the halfshaft
     

  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.

      Click image to see an enlarged view

      Fig. Exploded view of the halfshaft assembly



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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

    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.
  8.  
  9. Install or connect the following:

    Small ring clamp on the CV boot
     
    CV boot onto the halfshaft
     

  10.  
  11. 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.

  12.  
  13. Using a Crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm).
  14.  
  15. Install the remainder of the grease into the CV-joint boot.
  16.  
  17. Install or connect the following:

    New retaining ring on the halfshaft
     
    Outer race assembly onto the halfshaft until the ring engages the halfshaft groove
     
    Large ring clamp on the CV boot
     

  18.  
  19. Using a Crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. lbs. (176 Nm).
  20.  
  21. Install the halfshaft and the front wheel.
  22.  

 
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