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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 120 (AXLE SHAFTS)OVERHAULAXLE SHAFT INNER JOINT & BOOTREASSEMBLY
2001 Chevrolet Cavalier LS, 2.4 T

Axle Shaft Inner Joint & Boot: Reassembly

2001 Chevrolet Cavalier LS, 2.4 TSECTION Reassembly
WARNING: This page is about a different car, the 2003 Chevrolet Corvette and 2002 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Axle shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the axle shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the axle shaft.
  1. Wrap a shop towel around the axle shaft.
  2. Place the axle shaft horizontally in a bench vise.
  3. Install a NEW small seal retaining clamp onto the axle shaft.
  4. Install the boot onto the axle shaft.
  5. Install the cage onto the axle shaft so the smaller diameter end faces the vise.
    NOTE: The inner race spline relief must face away from the end of the axle shaft.
  6. Install the inner race onto the axle shaft.
    1. Engage the inner race splines onto the axle shaft splines. Be sure to install the inner race spline relief side onto the axle shaft first.
    2. Position a wood block squarely over the end of the inner race.
    3. Use a hammer to begin to drive the inner race onto the axle shaft.
    4. Reposition the wood block along the face of the inner race to avoid the axle shaft.
    5. Work evenly around the inner race and continue to drive the inner race, until you feel the inner race seat fully onto the axle shaft.
    6. Inspect to be sure that the axle shaft snap ring groove is exposed.
  7. Install the snap ring to the axle shaft. See Figure .
  8. Position the cage so the cage lands align with the inner race ball tracks.
  9. Install the cage onto the inner race.
  10. Position the cage windows to align with the inner race ball tracks.
  11. Insert approximately 60 percent of the grease from the service kit into the outer race.
  12. Position the axle shaft vertically in the bench vise so the inner joint end is up.
  13. Apply a small amount of the grease from the service kit to the cage windows and inner race ball tracks.
  14. Insert the remaining grease from the service kit into the boot.
  15. Install the outer race retaining ring onto the axle shaft. Position the retaining ring below the cage toward the vise.
  16. Install the balls through the cage windows to the inner race ball tracks. See Figure . Use the boot to keep the balls in position if necessary.
  17. Install the outer race onto the axle shaft. See Figure .
    1. Be careful not to allow the grease in the outer race to leak out.
    2. Align the outer race ball tracks to the balls.
    3. Slide the outer race down over the balls.
  18. Position the axle shaft horizontally in the bench vise.
  19. Engage the outer race retaining ring.
    1. Slide the outer race toward the vise.
    2. Insert the outer race retaining ring into the groove along the outer edge of the outer race.
    3. Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track).
  20. Position the large diameter end of the boot onto the outer race.
  21. Position the small seal retaining clamp onto the neck of the boot (seal). See Fig 1 . Position the boot and small retaining clamp to the axle shaft.
  22. Measure the distance of edge of seal-to-edge of the last axle shaft groove. See Fig 1 . Adjust to fit accordingly. See AXLE SHAFT SPECIFICATIONS  .
    NOTE: The seal retaining clamp must not be over-tightened or under-tightened.
  23. Crimp the small seal retaining clamp using the axle shaft seal clamp pliers. See Fig 2 . Tighten the small seal retaining clamp to specification. See AXLE SHAFT SPECIFICATIONS  . The clamping hold time must be no less than 2 seconds.
  24. Adjust the plunging motion of the inner joint to specification. See AXLE SHAFT SPECIFICATIONS  .
  25. Position the large seal retaining clamp onto the boot.
  26. Position the seal and large retaining clamp to the joint outer race. See Fig 4 . Measure the distance of edge of seal-to-end of joint outer race. See AXLE SHAFT SPECIFICATIONS  .
    NOTE: The boot must not be dimpled, stretched or out of shape in any way.
  27. Inspect the boot for proper shape. If the boot is not shaped correctly, equalize the pressure in the boot and shape the boot properly by hand.
  28. Inspect the boot for damage. If the boot has been cut or punctured during assembly, you must discard and replace the boot.
  29. Align the following items while latching:
    • The axle shaft inboard boot.
    • The inboard housing.
    • The large seal retaining clamp.
  30. Using the axle seal crimp pliers, latch the large seal retaining clamp. See Fig 5 . Ensure that the latching tangs are fully engaged in the large seal clamp band.
  31. Remove the axle shaft from the bench vise.
  32. Distribute the grease within the inner CV joint. Plunge the joint back and forth 4 or 5 times.
  33. Inspect the inner CV joint and axle shaft for smooth operation.
    1. Hold the axle shaft vertically, with the outer joint at the bottom.
    2. Rotate the axle shaft 4 or 5 times in a circular motion.
    To install the axle shaft into the vehicle, see AXLE SHAFTS  under REMOVAL & INSTALLATION.
Fig 1: Positioning Axle Shaft Small Seal Retaining Clamp
G00330630Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

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  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.