Solstice 2006-2008, Sky 2007-2008

Halfshafts

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CV-Joints



Overhaul
Inner Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft assembly from the vehicle.
  4.  
  5. Wrap a shop towel around the halfshaft bar.
  6.  
  7. Place the halfshaft horizontally in a bench vise.
  8.  
  9. Using a side cutter or other suitable tool, remove the large boot retaining clamp from the inner joint boot and discard the retaining clamp.
  10.  
  11. Using a side cutter or other suitable tool, remove the small boot retaining clamp from the inner joint boot and discard the clamp.
  12.  
  13. Slide the boot along the halfshaft bar away from the joint face.
  14.  
  15. Wipe the grease from the face of the joint inner race, cage, balls, etc.
  16.  
  17. Using snapring pliers, spread the ears of the joints inner race retaining ring.
  18.  
  19. Hold the inner joint horizontally to the shaft.
  20.  
  21. Position a brass drift on the inner race.
  22.  
  23. Carefully strike the brass drift with a hammer to remove the inner joint assembly from the halfshaft.
  24.  
  25. Remove and discard both halfshaft retaining rings from the axle shaft.
  26.  
  27. Remove the boot from the halfshaft.
  28.  
  29. Remove the small boot retaining clamp from the halfshaft.
  30.  
  31. Remove the halfshaft from the vise.
  32.  
  33. Wrap a shop towel around the joint outer race splined shaft.
  34.  
  35. Place the outer race vertically in a bench vise.
    NOTE
    All traces of old grease and any contaminates must be removed.

  36.  
  37. Clean all parts thoroughly with a safe solvent.
  38.  
  39. Thoroughly air dry all of the parts.
  40.  
  41. Inspect all parts for damage and/or wear.
  42.  

To install:

  1. Insert approximately 60 percent of the grease from the service kit into the inner joint. Spread the most of that 60 percent onto the ball tracks, the balls, the cage and the inner race. Spread the remainder of the grease into the bottom of the outer race.
  2.  
  3. Remove the inner joint from the bench vise.
  4.  
  5. Wrap a shop towel around the halfshaft.
  6.  
  7. Place the halfshaft horizontally in a bench vise.
  8.  
  9. Install a new small boot retaining clamp onto the halfshaft.
  10.  
  11. Slide the boot onto the halfshaft.
  12.  
  13. Place the new large retaining clamp over the large end of the boot.
  14.  
  15. Install the new halfshaft large retaining ring onto drive shaft.
  16.  
  17. Seat the new halfshaft large retaining ring into the large ring groove.
  18.  
  19. Install the new halfshaft small retaining ring onto drive shaft.
  20.  
  21. Seat the new halfshaft small retaining ring into the small ring groove.
  22.  
  23. Push the inner joint assembly onto the halfshaft until the small retaining ring seats itself in the retaining groove on the halfshaft.
  24.  
  25. Insert the remaining grease from the service kit into the boot.
  26.  
  27. Position the small boot retaining clamp onto the neck of the boot.

    Click image to see an enlarged view

    Fig. Position the boot and small retaining clamp to the halfshaft as shown

  28.  
  29. Position the boot and small retaining clamp to the axle shaft as shown.
    NOTE
    The boot retaining clamp must not be over-tightened or under-tightened.



    Click image to see an enlarged view

    Fig. Measuring the clamp gap

  30.  
  31. Using the crimping pliers, crimp the small boot retaining clamp. Tighten the small boot clamp until the base of the omega shape has a gap of 1 mm (0.039 in).
  32.  
  33. The clamping hold time must be no less than 2 seconds.
    NOTE
    The inner boot must not be dimpled, stretched, or out of shape in any way. If necessary, equalize the air pressure in the inner boot and shape properly by hand.

  34.  
  35. Position the large boot retaining clamp onto the boot.

    Click image to see an enlarged view

    Fig. Position the boot and large retaining clamp to the joint-s boot groove as shown

  36.  
  37. Position the boot and large retaining clamp to the joint-s boot groove as shown.

    Click image to see an enlarged view

    Fig. Measure the boot length

  38.  
  39. Measure the distance (1) between the boot edges. The gap should be 88.6 mm (3.50 in.)
    NOTE
    The boot must not be dimpled, stretched or otherwise deformed.

  40.  
  41. Inspect the boot for proper shape. If the boot is not shaped correctly, equalize the pressure in the boot by lifting the boot edge slightly and shape the boot properly by hand.
  42.  
  43. Inspect the boot for damage. If the boot has been cut or punctured during assembly, you must discard and replace the boot.
    NOTE
    The boot retaining clamp must not be over-tightened or under-tightened.

  44.  
  45. Crimp the large boot retaining clamp. Tighten the large boot clamp until the base of the omega shape has a gap of 1 mm (0.039 in.).
  46.  
  47. Inspect the inner joint for smooth operation. This will also distribute the grease within the joint.
    1. Hold the halfshaft vertically, with the inner joint at the bottom.
    2.  
    3. Rotate the halfshaft 4 or 5 times in a circular motion.
    4.  
    5. Install the halfshaft.
    6.  

  48.  

Outer Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the halfshaft from the vehicle.
  4.  
  5. Wrap a shop towel around the shaft.
  6.  
  7. Place the halfshaft horizontally in a bench vise.
  8.  
  9. Using a side cutter or other suitable tool, remove the large boot retaining clamp from the outer joint boot and discard the clamp.
  10.  
  11. Using a side cutter or other suitable tool, remove the small boot retaining clamp from the outer joint boot and discard the clamp.
  12.  
  13. Separate the boot from the joint outer race at the large diameter end.
  14.  
  15. Slide the boot away from the joint face.
  16.  
  17. Wipe the grease from the face of the joint inner race, cage, balls, etc.
  18.  
  19. Remove the outer joint from the axle shaft using the following steps:
    1. Hold the outer joint housing horizontally to the shaft.
    2.  
    3. Position a brass drift on the inner race.
    4.  
    5. Strike the brass drift with a hammer to compress the axle shaft retaining clip.
    6.  
    7. Continue to strike the brass drift in order to remove the outer joint from the axle shaft.
    8.  

  20.  
  21. Remove and discard the narrow retaining ring from the outer narrow ring groove at the end of the halfshaft.
  22.  
  23. Remove and discard the wide spacer ring from the wide ring groove of the halfshaft.
  24.  
  25. Remove the boot from the axle shaft.
  26.  
  27. Remove the halfshaft from the vise.
  28.  
  29. Wrap a shop towel around the joint outer race splined shaft.
  30.  
  31. Place the outer race vertically in a bench vise.
    NOTE
    All traces of old grease and any contaminates must be removed.

  32.  
  33. Clean all parts thoroughly with safe solvent.
  34.  
  35. Thoroughly air dry all of the parts.
  36.  
  37. Inspect all parts for damage and/or wear.
  38.  

To install:

  1. Insert approximately 60 percent of the grease from the service kit into the outer joint. Spread most of the grease onto the ball tracks, the balls, the cage, and the inner race. Spread the remainder of the grease into the bottom of the outer race.
  2.  
  3. Remove the inner joint from the bench vise.
  4.  
  5. Wrap a shop towel around the axle shaft.
  6.  
  7. Place the halfshaft horizontally in a bench vise.
  8.  
  9. Install a new small boot retaining clamp onto the axle shaft.
  10.  
  11. Install the boot onto the axle shaft.
  12.  
  13. Install the New narrow retaining ring to the outer narrow ring groove at the end of the halfshaft.
  14.  
  15. Install the New wide spacer ring to the wide ring groove of the halfshaft.
  16.  
  17. Position the outer joint horizontally.
  18.  
  19. Engage the inner race splines onto the axle shaft splines.
  20.  
  21. Compress the axle shaft ring spacer.
    1. Press the end of the retaining ring, using a flat-bladed tool, into the axle shaft groove while firmly pressing the inner joint onto the axle shaft.
    2.  
    3. Continue to work around the retaining ring, until it is compressed.
      NOTE
      The axle shaft and inner race must be fully seated to each other.

    4.  

  22.  
  23. Install the outer joint to the axle shaft.
    1. Position a wood block over the end of the outer joint threaded shaft.
    2.  
    3. Use a hammer to drive the outer joint onto the shaft.
    4.  
    5. Continue to drive the outer joint until the inner joint seats fully onto the axle shaft.
    6.  

  24.  
  25. Position the small boot retaining clamp into the boot groove.
  26.  
  27. Position the boot and small retaining clamp to the shaft boot groove as shown.
    NOTE
    The boot retaining clamp must not be over-tightened or under-tightened.

  28.  
  29. Crimp the small boot retaining clamp. Tighten the small boot clamp until the base of the omega ohms shape has a gap of 1 mm (0.039 in).
  30.  
  31. The clamping hold time must be no less than 2 seconds.
  32.  
  33. Insert the remaining grease from the service kit into the boot.
  34.  
  35. Position the large boot retaining clamp onto the boot.
  36.  
  37. Position the boot and large retaining clamp to the joint outer race as shown.
    NOTE
    The boot must not be dimpled, stretched, or otherwise deformed.

  38.  
  39. Inspect the boot for proper shape. If the boot is not shaped correctly, equalize the pressure in the boot by lifting the boot edge slightly and shape the boot properly by hand.
  40.  
  41. Inspect the boot for damage. If the boot has been cut or punctured during assembly, you must discard and replace the boot.
    NOTE
    The boot retaining clamp must not be over-tightened or under-tightened.

  42.  
  43. Crimp the large boot retaining clamp. Tighten the large boot clamp until the base of the omega ohms shape has a gap of 1 mm (0.039 in).
  44.  
  45. The clamping hold time must be no less than 2 seconds.
  46.  
  47. Inspect the outer joint for smooth operation. This will also distribute the grease within the joint.
    1. Hold the halfshaft vertically, with the outer joint at the bottom.
    2.  
    3. Rotate the halfshaft 4 or 5 times in a circular motion.
    4.  
    5. Install the halfshaft.
    6.  

  48.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the rear brake rotor.
    WARNING
    The wheel drive shaft spindle nut must not be reused. Replace the wheel drive shaft spindle nut with a new nut whenever it is removed.

  8.  
  9. Remove and discard the wheel drive shaft spindle nut.
  10.  
  11. Using a Universal Hub Puller, disengage the wheel drive shaft from the wheel bearing/hub.
  12.  
  13. Remove the adjustment link.
  14.  
  15. Separate the upper ball joint from the rear knuckle.
  16.  
  17. Using a suitable tool, carefully release the wheel drive shaft from the rear differential enough to install the J 44394 seal protector.
    WARNING
    J-44394 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install J-44394 as indicated may cause the splines of the wheel drive shaft to cut the differential output seal.



    Click image to see an enlarged view

    Fig. Releasing the wheel drive shaft from the rear differential

  18.  
  19. Carefully install the J 44394 over the wheel drive shaft
  20.  
  21. Carefully slide the J 44394 into the differential output shaft seal.
  22.  
  23. Remove the wheel drive shaft from the vehicle.
  24.  
  25. If reusing the wheel drive shaft, remove and discard the wheel drive shaft retaining ring. The wheel drive shaft retaining ring is on the splined shaft of the cross groove joint.
  26.  

To install:

  1. Install the new wheel drive shaft retaining ring. The wheel drive shaft retaining ring is on the splined shaft of the cross groove joint.
  2.  
  3. If previously removed, carefully install J 44394 into the differential output shaft seal.
    NOTE
    In order to prevent lubricant leaks, use care when installing the wheel drive shaft to the differential. Do not damage the oil seal. Replace the oil seal if it becomes nicked, distorted, or is otherwise damaged.



    Click image to see an enlarged view

    Fig. J 44394 installed into the differential output shaft seal

  4.  
  5. Carefully install the wheel drive shaft into the differential until the splines are past the J 44394. Ensure that the retaining ring is installed in the upright position.
  6.  
  7. Carefully remove the J 44394 from the differential output shaft seal.
  8.  
  9. Carefully remove J 44394 from the wheel drive shaft.

    Click image to see an enlarged view

    Fig. J 44394 removal from the differential output shaft seal

  10.  
  11. Carefully install the wheel drive shaft into the differential until the retaining ring is engaged.
  12.  
  13. Ensure the wheel drive shaft retaining ring is fully engaged to the differential by grasping the inner housing and pulling outward. The wheel drive shaft will stay positively engaged if properly installed to the differential.
  14.  
  15. Install the upper ball joint to the rear knuckle.
  16.  
  17. Loosely install the new wheel drive shaft spindle nut.
  18.  
  19. Install the adjustment link.
  20.  
  21. Use the new wheel drive shaft spindle nut to slowly pull the spindle to the wheel hub and bearing assembly.
  22.  
  23. Tighten the wheel drive shaft spindle nut to 159 ft. lbs. (215 Nm).
  24.  
  25. Install the rear brake rotor.
  26.  
  27. Install the tire and wheel assembly.
  28.  
  29. Inspect the differential lubricant level.
  30.  
  31. Lower the vehicle.
  32.  

 
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