GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Driveline/Axle 🢒 Wheel Drive Shafts 🢒 Wheel Drive Shaft Overhaul

    Object Number: 860858 Size: SH

    Notice: Use soft metal or wood in between vice jaws to protect the shaft.

  1. Clamp the drive axle shaft in a vice.

    2. Object Number: 861896 Size: SH
  2. Remove the outer CV joint and joint boot.
    3. 2.1. Use a hammer and chisel or a flat-blade screw driver to disengage the outer band from the inner band at the retainer peg on both large and small boot clamps and discard the clamps.
    2.2. Separate the joint boot from the CV joint race at the large diameter and slide the boot away from the joint along the axle shaft.
    2.3. Wipe the excess grease from the face of the CV inner race.

    Object Number: 891620 Size: SH
  3. Using a rubber mallet, or block of wood and hammer, carefully tap on the CV joint to remove it from the axle.
  4. Remove the boot from the axle shaft.

    5. Object Number: 891511 Size: FP
  5. Disassemble the CV joint.
    6. 5.1. Using a brass drift, gently tap on the cage until it is tilted enough to remove the first ball.
    5.2. Remove the remaining balls in a similar manner.
    5.3. With all the balls removed, pivot the cage and inner race at 90 degrees to the center line of the outer race with the cage windows aligned with the lands of the outer race, lift out the cage and the inner race.
    5.4. Rotate the inner race up and out of the cage.
    5.5. Thoroughly degrease all CV joint parts and allow them to dry prior to assembly.
  6. Assemble the CV joint.
    7. 6.1. Inspect the parts for unusual wear, cracks and other damage. Replace the joint assembly if needed.
    6.2. Put a light coat of recommended grease on the inner and outer race grooves.
    6.3. Insert and rotate the inner race into the cage.
    6.4. Install the cage and the inner race into the outer race with the windows of the cage aligned with the lines of the outer race.
    6.5. Install the balls using a brass drift to gently rotate and position the cage and the inner race.
    6.6. Pack the assembled joint with the grease provided in the service kit. The amount of grease supplied with the service kits has been pre-measured for each application.

    Object Number: 891517 Size: SH
  7. Remove tri-pot joint and joint boot.
    8. 7.1. Cut eared boot retaining clamp on tri-pot boot with side cutters and discard.
    7.2. Remove earless clamp, using a small-blade screwdriver and discard.

    Object Number: 891521 Size: SH
  8. Separate boot from tri-pot housing at large diameter and slide boot away from joint along axle shaft.
  9. Wipe excess grease from face of tri-pot spider and inside of tri-pot housing.
  10. Remove tri-pot housing from the spider and shaft.

    11. Notice: Handle the tri-pot spider assembly with care. Tri-pot balls and needle rollers may separate from spider trunnions.


    Object Number: 891621 Size: SH
  11. Remove spider retaining ring from groove on axle shaft and slide spider assembly off of shaft.
  12. Remove boot from axle shaft.
  13. Thoroughly degrease the tri-pot housing and allow to dry prior to assembly.