S10 Pickup, Sonoma 2000-2004

CV-Joints

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Overhaul



Inner CV-Joint & Boot

NOTE
This procedure requires the use of the following: J 35566 Drive Axle Seal Clamp Pliers, J 41048 Swage Clamp Tool and J 8059 Snap Ring Pliers, or equivalent tools.

  1. Remove or disconnect the following:
    NOTE
    Be careful not to damage the tripot housing.



    Front wheel
     
    Halfshaft and place it in a vise
     
    Clamp from the boot with a pair of side cutters.
     

  2.  
  3. Use a hand grinder to cut through the swage ring.
    NOTE
    Handle the tripot spider assembly with care or the tripot balls and needle rollers may separate from the spider trunnion.



    Tripot housing and the trilobal tripot bushing from the halfshaft bar. Thoroughly degrease the housing and the spider assembly. Discard the tripot bushing. Use 320 grit 3M cloth (or equivalent) to remove any evident corrosion in the transmission sealing surface. Allow the housing and the spider assembly to dry .
     

  4.  
  5. Compress the tripot boot onto the halfshaft bar, away from the spider assembly
  6.  
  7. Spread the spacer rings using Snap Ring Pliers J 8059, or equivalent, to remove the spider assembly.
  8.  
  9. Remove the following items:

    The spacer ring
     
    The spider assembly
     
    The second spacer ring
     
    The tripot boot
     

  10.  
  11. Discard the tripot boot and spacer rings. Clean the halfshaft bar. Use a wire brush to remove any rust in the boot mounting area (grooves). Inspect the needle rollers, needle bearings and the trunnion. Inspect the tripot housing for unusual wear, cracks, or other damage. Use the appropriate kit to replace any damaged parts.
  12.  

To install:

  1. Position the new swage clamp onto the neck of the boot. Do not swage. Slide the new small swage clamp and the boot to the proper position on the halfshaft bar.
  2.  
  3. Position the neck of the boot in the boot groove on the halfshaft bar. In order to swage the swage clamp, position the inboard end of the halfshaft assembly in Swage Clamp Tool J 41048, or equivalent. align the swage clamp within J 41048.
  4.  
  5. Place the top half of the Swage Clamp Tool J 41048 on the bottom half. Check to make sure there are no pinch points on the boot before continuing. Insert the bolts and tighten by hand until snug.
  6.  
  7. Align the boot, the halfshaft bar and the swage clamp. Tighten each bolt 180 degrees at a time, using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
  8.  
  9. Loosen the bolts and separate the dies.
    NOTE
    If deformities exist in the swage clamp, place the swage clamp back into the Swage Clamp Tool. Make sure the swage clamp covers the whole swaging area. Re-swage the swage clamp.

  10.  
  11. Inspect the swage clamp for any "lip" deformities.
  12.  
  13. Assemble the joint with the convolute retainer in the correct position. Assemble the joint to meet the specified dimension to avoid boot damage.
  14.  
  15. Install the convolute retainer over the boot capturing four convolutions
  16.  
  17. Install the spacer ring and spider assembly onto the halfshaft bar. Install the other spacer ring in the groove at the end of the halfshaft bar. Ensure that the rings are fully seated.
  18.  
  19. Pack the boot and housing with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
  20.  
  21. Place the large retaining clamp on the boot. Place the housing and the new trilobal tripot bushing over the spider assembly.
  22.  
  23. Install the boot onto the trilobal tripot bushing.
  24.  
  25. Measure the inboard stroke position (see accompanying diagram):
    1. For male tripot housing assembly: dimension a = 11 in. (280mm).
    2.  
    3. For female tripot housing assembly: dimension b = 9 in. (228mm).

      Click image to see an enlarged view

      Fig. Measure the inboard stroke position as shown

    4.  

  26.  
  27. Secure the large retaining clamp and the boot to the housing using Drive Axle Seal Clamp Pliers J 35566, or equivalent.
  28.  
  29. Remove the convolute retainer from the boot.
  30.  
  31. Install the halfshaft and the front wheel.
  32.  

Outer CV-Joint

NOTE
This procedure requires the use of the following: J 35910 Seal Clamp Tool, J 41048 Swage Clamp Tool and J 8059 Snap Ring Pliers, or equivalent tools.

  1. Remove or disconnect the following:

    Front wheel
     
    Halfshaft and place it in a vise. Use protective covers on the vise to avoid damaging the halfshaft.
     

  2.  
  3. Use a hand grinder to cut through the swage rings. Do not damage the outer race.
  4.  
  5. Compress the seal on the halfshaft and away from the CV-joint outer race. Wipe all grease away from the face of the CV-joint.
  6.  
  7. Find the halfshaft retaining snapring, which is in the inner race. Spread the snapring ears apart using Snapring Pliers J-8059, or equivalent.
  8.  
  9. Pull the outer CV-joint from the halfshaft. Discard the old seal.
  10.  
  11. 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.  

  12.  
  13. 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.
    8.  

  14.  
  15. Thoroughly clean and inspect all parts.
  16.  

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. Pack the CV-joint seal and the CV-joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application.
  8.  
  9. Place the new small swage clamp onto the CV-joint seal.
  10.  
  11. Place the large retaining clamp on the seal.
  12.  
  13. Position the small end of the CV-joint seal into the joint seal groove on the halfshaft bar.
  14.  
  15. Position the outboard end of the halfshaft assembly in Swage Clamp Tool J 41048, or equivalent. Align the swage clamp within the clamp tool.
  16.  
  17. Place the top half of the Swage Clamp Tool J 41048 on the bottom half. Check to make sure there are no pinch points on the seal before proceeding with procedures. Insert the bolts and tighten by hand until snug.
  18.  
  19. Align the seal, the halfshaft bar and swage clamp. Tighten each bolt 180 degrees at a time, using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
  20.  
  21. Loosen the bolts. Separate the dies. Check the swage clamp for any "lip" deformities. If the deformities exist, place the swage clamp back into the Swage Clamp Tool J 41048.
  22.  
  23. Make sure the retaining ring side of the CV-joint inner race faces the halfshaft bar before installation.
  24.  
  25. Place the retaining snapring into the CV-Joint inner race.
    NOTE
    The retaining snapring inside of the inner race will engage in the halfshaft bar groove with a -click- when the CV-Joint is in the proper position.

  26.  
  27. Slide the CV-Joint onto the halfshaft bar. Pull on the CV-Joint to be sure it is properly engaged.
  28.  
  29. Slide the large diameter of the CV-Joint seal, with the large retaining ring in place, over the outside edge of the CV-Joint outer race.
  30.  
  31. Position the lip of the CV-Joint seal into the groove on the CV-Joint outer race. Make sure to remove any excess air from the CV-Joint seal.
    NOTE
    Make sure the boot lies flat against the outer race.

  32.  
  33. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. lbs. (176 Nm).
  34.  
  35. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tightening the clamp until it is.
  36.  
  37. Install the halfshaft and the front wheel.

    Click image to see an enlarged view

    Fig. Exploded view of the CV-Joint Assembly

  38.  

 
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