Montana SV6 (2006), Relay, Terraza, Uplander (2005-2007)

Halfshafts

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CV-Joints



Overhaul
  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

  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 (2) from the tripot joint with side cutters. Discard the large seal retaining clamp.
  6.  
  7. Separate the inboard seal from the tri-lobal tripot bushing (3) at the large diameter.

    Click image to see an enlarged view

    Fig. Exploded view of the front CV-Joint assembly

  8.  
  9. Slide the seal away from the joint along the halfshaft bar.
  10.  
  11. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2).

    Click image to see an enlarged view

    Fig. Removing the housing (1) from the tripot joint spider (CV joint) and the halfshaft bar (2)

  12.  
  13. Spread the spacer ring (1) using J 8059 (or equivalent).
  14.  
  15. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using J 8059, and tripot boot (4). Discard the boot and rings.
  16.  
  17. Clean the halfshaft bar (5). 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.

    Click image to see an enlarged view

    Fig. Disassembling the CV joint components: spacer ring (1), spider assembly (2), spacer ring (3), tripot boot (4), halfshaft bar (5)

  20.  

To install:

Click image to see an enlarged view

Fig. Assembling the CV joint components: joint seal (1), swage ring (2), joint seal groove (3)

  1. Place the new small swage ring or eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the small swage ring or eared clamp (2) onto the halfshaft bar.
  2.  
  3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.

    Click image to see an enlarged view

    Fig. Installing the swage ring, using a J 41048 holding tool. Position inboard end (1) into tool, assemble J 41048, tighten tool bolts (2) and align components

  4.  
  5. For swage ring installation, mount J 41048 in a vise and proceed as follows:
  6.  
  7. Position the inboard end (1) of the halfshaft assembly in tool J 41048.
  8.  
  9. Align the top of the seal neck on the bottom die using the indicator.
  10.  
  11. Place the top half of the J 41048 on the lower half.
    CAUTION
    Before proceeding, ensure there are no pinch points on the halfshaft inboard seal. This could cause damage to the halfshaft inboard seal.

  12.  
  13. Insert the bolts (2).
  14.  
  15. Tighten the bolts by hand until snug.
  16.  
  17. Align the following items:

    Halfshaft inboard seal (1)
     
    Halfshaft bar
     
    Swage ring (2)

    Click image to see an enlarged view

    Fig. Assembling the eared clamp with special tool J 35910 to properly crimp clamp

     

  18.  
  19. Tighten each bolt of the clamping tool (J 41048) 180 degrees at a time using a ratchet wrench.
  20.  
  21. Alternate between each bolt until both sides are bottomed.
  22.  
  23. For eared clamp installation, mount the halfshaft into a vise.
  24.  
  25. Slide the tripot seal (7) to the corresponding groove on the halfshaft bar.
  26.  
  27. Crimp the eared clamp (6) using J 35910, a torque wrench (8), and a breaker bar (9).

    Click image to see an enlarged view

    Fig. Installing spacer ring into halfshaft bar groove, using J 8059 ring pliers

  28.  
  29. If equipped, install the spacer ring (2) into the groove of the halfshaft bar using J 8059.
  30.  
  31. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar.
  32.  
  33. Install the spacer ring (2) into the groove of the halfshaft bar J 8059.
  34.  
  35. 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.
    CAUTION
    Ensure the tri-lobal tripot bushing (3) is flush with the face of the housing (1).



    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint assembly

  36.  
  37. Install the tri-lobal tripot bushing (3) to housing (1).
  38.  
  39. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal.
  40.  
  41. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.

    Click image to see an enlarged view

    Fig. Installing joint assembly to proper dimension (-a-)

  42.  
  43. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the tri-lobal tripot bushing and locate the lip of the seal in the groove.
    CAUTION
    The halfshaft inboard seal must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard seal is not shaped correctly, carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the tri-lobal tripot bushing in order to equalize the pressure. Shape the halfshaft inboard seal properly by hand. Remove the tool.

  44.  
  45. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in).
  46.  
  47. Align the following items while latching:

    Halfshaft inboard seal
     
    Tripot housing
     
    Large seal retaining clamp
     

  48.  
  49. Crimp the seal retaining clamp with J 35910 to 130 ft. lbs. (176 Nm). Add the breaker bar and the torque wrench to J 35910 if necessary.
  50.  
  51. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 0.102 inch (2.6mm) is reached.
  52.  
  53. Fully stroke the joint several times to disperse the grease.
  54.  

Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of the front halfshaft assembly

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel, marking the location of the wheel to the hub prior to removal. Mark the individual location of all retainers as they are removed.
  4.  
  5. Remove the engine splash shield.
  6.  
  7. Insert a drift or punch (1) through the brake caliper and into the brake rotor in order to prevent the wheel hub and bearing from turning.

    Click image to see an enlarged view

    Fig. Using drift through brake caliper to hold wheel hub and bearing from turning

  8.  
  9. Remove the halfshaft spindle nut (2).
  10.  
  11. Remove the stabilizer shaft link.
  12.  
  13. Disconnect the outer tie rod end from the steering knuckle; do NOT loosen the tie rod end jam nut.
  14.  
  15. Disconnect the electrical connector from the wheel speed sensor and reposition the wiring harness away from the ball joint.
  16.  
  17. Disconnect the lower ball joint from the steering knuckle.
  18.  
  19. Install the puller/remover J 42129 onto the wheel hub and secure with wheel nuts.
    CAUTION
    Be sure to support the halfshaft until it is fully removed from the vehicle.

  20.  
  21. Using the puller/remover tool, disengage the halfshaft from the wheel hub and bearing.
  22.  
  23. Assemble the special slide hammer and tool attachments (J 33008-A, J 29794, J 2619-O1) and disengage the halfshaft from the transaxle.
  24.  
  25. Remove the halfshaft from the vehicle

    Click image to see an enlarged view

    Fig. Removing/installing the front halfshaft

  26.  

To install:

  1. Install the halfshaft to the transaxle
    NOTE
    Verify that the wheel halfshaft is properly engaged to the transaxle by grasping the inner tripot housing and pulling outward. Do not pull on the halfshaft bar. The wheel halfshaft will remain firmly in place when properly engaged.



    Click image to see an enlarged view

    Fig. Installing the hub and bearing (2) to the halfshaft (1), with retaining nut (3)

  2.  
  3. Install or connect the following:
    NOTE
    Insert a drift or punch through the brake caliper and into the brake rotor in order to prevent the hub and bearing from turning.



    Halfshaft to the hub and bearing 
     
    Ball joint to the steering knuckle. See Lower Control Arm
     
    Wheel speed sensor electrical connector
     
    Stabilizer shaft link. See Stabilizer Bar under FRONT SUSPENSION.
     



    Install the nut to the halfshaft spindle and tighten the nut to 118 ft. lbs. (160 Nm)
     
    Outer tie rod end to the steering knuckle. See Tie Rod Ends
     
    Engine splash shield
     

  4.  
  5. Install the tire and wheel assembly. Tighten the lug nuts to 100 ft. lbs. (140 Nm) in a criss-cross pattern, after aligning the wheel hub with the reference mark and holes as shown in appropriate illustration.
  6.  
  7. Lower the vehicle.
  8.  

 
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