GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 RELAY - AWD 🢒 Driveline/Axle 🢒 Wheel Drive Shafts 🢒 Wheel Drive Shaft Inner Joint and Boot Replacement

Special Tools
    • J 8059 Snap Ring Pliers (Parallel Jaw)
    • J 35910 Drive Axle Seal Clamp Pliers

Removal Procedure

    Object Number: 238942 Size: SH

    Notice: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

  1. Disconnect the swage ring from the shaft using a hand grinder to cut through the ring, taking care not to damage the shaft.
  2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp.
  3. Separate the inboard boot from the trilobal tripot bushing (3) at the large diameter.
  4. Slide the boot away from the joint along the shaft.

    5. Object Number: 238938 Size: SH
  5. Remove the housing (1) from the tripot joint spider and the shaft (2).

    6. Object Number: 1575266 Size: SH
  6. Spread the spacer ring (1) using J 8059 (or equivalent).

    7. Object Number: 233581 Size: SH
  7. Remove the spacer ring (1), spider assembly (2), spacer ring (3), if equipped, using J 8059 , and tripot boot (4). Discard the boot and rings.
  8. Clean the shaft (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves).
  9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit.

Installation Procedure

    Object Number: 214024 Size: SH

    Important: Place a towel in the vise before inserting the shaft.

  1. Mount the shaft into a vise.
  2. Place the new small eared clamp (2) onto the small end of the joint boot (1). Slide the joint boot (1) and the eared clamp (2) onto the shaft.
  3. Position the small end of the joint boot (1) into the joint seal groove (3) on the shaft.

    4. Object Number: 256109 Size: SH
  4. Crimp the eared clamp (6) using J 35910 , a torque wrench (8), and a breaker bar (9).

    5. Object Number: 233593 Size: SH
  5. If equipped, install the spacer ring (2) into the groove of the shaft using J 8059 .

    6. Object Number: 256137 Size: SH
  6. Slide the tripot joint spider assembly (4) as far as it will go on the shaft.
  7. Install the spacer ring (2) into the groove of the shaft J 8059 .

    8. Object Number: 233615 Size: SH
  8. Place approximately half of the grease from the service kit in the shaft inboard boot. Use the remainder of the grease to repack the housing.

    9. Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

  9. Install the trilobal tripot bushing (3) to housing (1).
  10. Position the larger new seal retaining clamp (2) on the shaft inboard boot.
  11. Slide the housing (1) over the tripot joint spider assembly on the shaft.

    12. Object Number: 221916 Size: SH
  12. Slide the large diameter of the shaft inboard boot (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.
  13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in).
  14. Carefully insert a thin flat blunt tool, no sharp edges, between the large boot opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool.

    15. Object Number: 221910 Size: SH
  15. Align the following items while latching:
    16. • The shaft inboard boot
    • The tripot housing (2)
    • The large boot retaining clamp (3)

    Tighten
    Crimp the boot retaining clamp with J 35910 to 176 N·m (130 lb ft). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary.

  16. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 2.6 mm (0.102 in) is reached.
  17. Fully stroke the joint several times to disperse the grease.