FRONT PROPELLER SHAFT CV BOOT TORN OR CRACKED

REVISION: 09/30/98 DIVS INVL 1 3 5 7

THIS BULLETIN IS BEING REVISED TO ADD A MODEL AND ADD MODEL YEARS. PLEASE DISCARD CORPORATE BULLETIN NUMBER 46-41-02 (SECTION 4 - DRIVE AXLE). ______________________________________________________________________

SUBJECT: FRONT PROPELLER SHAFT CV BOOT TORN OR CRACKED (INSTALL NEW CV JOINT AND BOOT)

MODELS: 1992-98 CHEVROLET AND GMC L VAN MODELS 1995-97 GMC JIMMY EQUIPPED WITH RPO F46 1991-94 OLDSMOBILE BRAVADA 1996-97 OLDSMOBILE BRAVADA EQUIPPED WITH RPO F46

CONDITION:

SOME OWNERS MAY COMMENT THAT THE FRONT PROPELLER SHAFT CONSTANT VELOCITY (CV) JOINT BOOT MAY BECOME TORN OR CRACKED CAUSING THE CV JOINT TO BECOME NOISY. FAILURE OF THE CV JOINT MAY CAUSE A DRIVELINE VIBRATION AND MAY PRODUCE A DARK BROWN MILKY GREASE TO EMIT FROM THE END OF THE JOINT BREATHER HOLE. OWNERS MAY NOT NOTICE THIS CONDITION UNTIL A GREASE SPOT APPEARS UNDER THE VEHICLE OR WHEN THE VEHICLE IS SERVICED FOR ROUTINE MAINTENANCE.

CAUSE:

CONDITIONS MAY BE CAUSED FROM THE CV JOINT BOOT MATERIAL BECOMING DAMAGED AT THE CLAMP AREA, OR THE LARGE RING RETAINER FOR THE OUTSIDE DIAMETER OF THE BOOT DISLODGES AND THE LUBRICATION WITHIN THE CV JOINT ESCAPES CAUSING THE CV JOINT TO BECOME NOISY.

CORRECTION:

TO REPAIR THIS CONDITION, A SERVICE PROCEDURE HAS BEEN DEVELOPED WHICH INCLUDES THE REPLACEMENT OF AN ASSEMBLED FRONT CV JOINT AND BOOT WITH A NEW CLAMP AND FILLED WITH GREASE.

SERVICE PROCEDURE

REMOVAL PROCEDURE (FIGURES 1, AND 2)

1. RAISE THE VEHICLE ON A HOIST.

2. REMOVE THE PROPELLER SHAFT ATTACHING BOLTS FROM THE TRANSFER CASE (FIGURE 1, ITEM 2).

3. REMOVE THE PROPELLER SHAFT ATTACHING BOLTS FROM THE FRONT AXLE PINION FLANGE (FIGURE 1, ITEM 3).

4. REMOVE THE FRONT PROPELLER SHAFT (FIGURE 1, ITEM 1) FROM THE VEHICLE.

5. SECURE FRONT PROPELLER SHAFT HORIZONTALLY IN A VISE.

6. REMOVE THE BOOT CLAMP.

7. USING A CUTTING TOOL, REMOVE ENOUGH OF THE RUBBER BOOT (FIG 2, ITEM 1) FROM THE CV JOINT (FIG 2, ITEM 5) IN ORDER TO GAIN ACCESS TO THE SHAFT'S "CAPTURED" SNAP RING INSIDE THE CV JOINT HOUSING.

8. OPEN THE SNAP RING AND PULL THE SHAFT (FIG 2, ITEM 4) AWAY FROM THE CV JOINT HOUSING (FIG 2, ITEM 5).

9. CLEAN OFF THE END OF THE OLD STUB SHAFT.

INSTALLATION PROCEDURE (FIGURES 1, 2, AND 3)

TOOL REQUIRED KENT MOORE J-35910 CLAMP INSTALLER

1. INSTALL LOOSE BOOT CLAMP ON THE CV JOINT BOOT PRIOR TO INSERTING THE END OF THE OLD SHAFT INTO THE NEW CV JOINT KIT.

2. FORCIBLY PUSH THE SHAFT IN THE NEW CV JOINT IN ORDER TO ENGAGE THE SNAP RING ON THE SHAFT. AN AUDIBLE SOUND SHOULD BE HEARD WHEN ENGAGEMENT OF SNAP RING OCCURS ON THE SHAFT. VERIFY ENGAGEMENT OF THE SNAP RING TO THE SHAFT BY ATTEMPTING TO SEPARATE BOTH COMPONENTS.

3. LOCATE THE BOOT CLAMP IN THE GROOVE OF THE BOOT SEAL GROOVE FOR THE CLAMP.

4. USING THE CLAMP INSTALLER TOOL WITH A BREAKER BAR AND TORQUE WRENCH, CRIMP THE BOOT CLAMP INTO POSITION ON THE CV JOINT BOOT (FIG 3). LEAVE APPROXIMATELY 1/16 INCH OF A GAP IN THE BOOT CLAMP (FIG 3).

5. RE-INSTALL THE FRONT PROPELLER SHAFT INTO THE VEHICLE. THERE ARE NO "ALIGNMENT" MARKS ON THE NEW JOINT FOR A BALANCE REFERENCE. TIGHTEN: - BOLTS TO TRANSFER CASE TO 125 N.M (92 LB FT) (FIGURE 1, ITEM 2). - BOLTS TO FRONT AXLE FLANGE TO 72 N.M (53 LB FT) (FIGURE 1, ITEM 3).

6. ROAD TEST THE VEHICLE FOR DRIVELINE DISTURBANCES. IF THE ROAD TEST REVEALS A DISTURBANCE, RE-INDEX THE FRONT PROPELLER SHAFT ON THE AXLE FLANGE. IF AFTER 3 ATTEMPTS AT RE-INDEXING THE PROPELLER SHAFT STILL DOES NOT ACHIEVE AN ACCEPTABLE BALANCE, USE THE ELECTRONIC VIBRATION ANALYZER (EVA) TO SYSTEM BALANCE THE FRONT PROPELLER SHAFT. REFER TO SECTION 0C OF THE APPROPRIATE SERVICE FOR FURTHER DETAILS).

PARTS INFORMATION:

P/N DESCRIPTION QTY 26047645 KIT (CROSS-GROOVE AND BOOT) 1

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION DESCRIPTION LABOR TIME --------- ----------- ---------- F1200 PROPELLER SHAFT, FRONT OF USE PUBLISHED TRANSFER CASE - REPLACE LABOR OPERATION TIME

FIGURES: 3 CAPTIONS: FIGURE 1 - FRONT PROPELLER SHAFT ITEM 1- FRONT PROPELLER SHAFT ITEM 2- BOLT TO TRANSFER CASE FLANGE ITEM 3- BOLT TO FRONT AXLE FLANGE FIGURE 2 - CONSTANT VELOCITY JOINT ITEM 1- CV JOINT BOOT ITEM 2- CV JOINT BOOT CLAMP ITEM 3- CV JOINT FLANGE ITEM 4- FRONT PROPELLER SHAFT ITEM 5- CV JOINT FIGURE 3 - CRIMPING RETAINING CLAMP

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

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