GM Service Manual Online
For 1990-2009 cars

Removal Procedure

Tools Required

    • J 42066 Wheel Hub Flange Holding Adapter
    • J 42071 Drive Axle Separator
  1. Place the gear selector in the NEUTRAL position.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the tire and wheel assembly. Refer to Wheel Removal .

  4. Object Number: 218877  Size: SH
  5. Install the J 42066 to the wheel hub flange with the wheel bolts.

  6. Object Number: 218879  Size: SH
  7. Remove the bolts (1) from the drive axle flange (2) while holding the J 42066 with a ratchet.

  8. Object Number: 218881  Size: SH
  9. Separate the outer end of the drive axle from the wheel bearing hub inner flange.

  10. Object Number: 218885  Size: SH

    Important: Ensure that the beveled side of the J 42071 , labeled Differential Side, is against the differential and not against the drive axle or damage to the ABS sensor reluctor ring may occur.

  11. Use the J 42071 and a deadblow hammer to separate the drive axle from the rear axle differential.
  12. Remove the drive axle from the vehicle.
  13. Clean the drive axle spline.
  14. Clean the seal surfaces.

GKN Drive Axle Disassembly

Important: The following overhaul procedures apply to the outer constant velocity joint only. The inner joint cannot be serviced. If the inner joint requires service, the entire drive axle assembly must be replaced.

The GKN drive axle is identified by its shaft diameter and by the axle manufacturer's markings on the outer surface of the inner joint. This marking contains the Made in Germany phrase along with some other manufacturing data. The diameter of the GKN axle shaft should measure about 32.1 mm (1.26 in). The Delphi/Saginaw axle will most likely be found on mid year and on later Cateras. The Delphi/Saginaw axle contains slightly smaller drive axle shafts measuring 27.7 mm (1.09 in) in diameter.

  1. Clean the outside of the drive axle using a suitable solvent before disassembling.
  2. Clamp the drive axle at the shaft surface in a soft metal-jawed vice.

  3. Object Number: 218888  Size: SH
  4. Using tin snips or another suitable cutting tool, cut both the inner (3) and outer (1) boot retaining clamps in the raised crimp area.
  5. Perform the step that applies below:
  6. • If replacing the boot, remove the clamps.
    • If not replacing the boot, slide the cap and the boot slightly down the axle shaft in order to expose the outer constant velocity joint without destroying the clamps.

    Object Number: 218892  Size: SH
  7. Using a suitable drift and a hammer, tap the inner/outer dust shield caps away from both sides of the outer constant velocity joint.
  8. Clean away any grease from the following components:
  9. • The drive axle shaft
    • The outer constant velocity joint

    Object Number: 219007  Size: SH
  10. Remove the retaining ring (1) from the drive axle shaft (2).
  11. Discard the retaining ring.
  12. Remove the drive axle shaft from the vice.
  13. Slide the inner dust shield boot and cap toward the center of the shaft in order to expose the bottom of the outer constant velocity joint.

  14. Object Number: 219008  Size: SH

    Important: Inspect that the inner race is fully supported in the press during the next step.

  15. Install the drive axle onto a press, ensuring that the inner race is fully supported.
  16. Important: Do not attempt to disassemble the outer constant velocity joint until the joint is removed from the drive axle shaft.

  17. Press the drive axle shaft from the outer constant velocity joint.
  18. If replacing or removing the boot for cleaning, perform the following steps:
  19. 13.1. Loosen the inner boot clamp.
    13.2. Carefully slide the boot and the dust shield off of the drive axle shaft in order to prevent damage to the boot from the shaft spline edges.
  20. Clean the following components using a suitable solvent:
  21. 14.1. The drive axle shaft
    14.2. The boot
  22. Inspect the drive axle shaft for twisting, cracking, or excessive spline wear. Replace as needed.
  23. Inspect the boots for splits, fatigue, cracks, or wear. Replace as needed.
  24. If replacing the drive axle, remove the ABS sensor reluctor ring from the inner constant velocity joint.

GKN Outer Constant Velocity Joint Disassembly

Important: 

   • Complete disassembly of the outer constant velocity joint is not recommended. The internal components are a precision fit and develop their own characteristic wear patterns.
   • Do not intermix components from another joint. This may result in looseness, binding, or premature failure of the joint.
   • Should the joint become inadvertently disassembled, follow the assembly procedure EXACTLY.

Inspection


    Object Number: 219012  Size: SH
  1. Inspect the grease in the joint:
  2. • If contaminated, replace the joint.
    • If not contaminated, clean the joint using a suitable solvent.
  3. Tilt the inner race to one side in order to expose each ball bearing for inspection.
  4. Replace the joint if any of the following conditions exist:
  5. • Any severe pits, galls, or play between the balls and the cage windows
    • Any cracks or other damage to the cage
    • Any pits, galls, or chips in the raceway

    Object Number: 219015  Size: SH
  6. If the joint becomes disassembled during the inspection, perform the following steps:
  7. 4.1. Note the identification groove (1) on the outer race and identification step (2) of the inner race for proper orientation upon reassembly.
    4.2. Refer to the Important notice above before reassembling.

GKN Outer Constant Velocity Joint Assembly

  1. Lightly grease the inner/outer race ball bearing contact surfaces.

  2. Object Number: 219017  Size: SH
  3. Position the inner race in the center of the cage.

  4. Object Number: 219021  Size: SH
  5. Place the inner race/cage assembly (2) into the outer race (1), using the markings as noted during disassembly.

  6. Object Number: 219015  Size: SH
  7. Inspect that the identification markings on both the inner (2) and outer (1) races are on opposite sides.

  8. Object Number: 219025  Size: SH
  9. Align the thick sections on the outer race (2) with the narrow sections on the inner race (1).

  10. Object Number: 219029  Size: SH
  11. Tilt the cage and inner race, fitting each ball one at a time.

  12. Object Number: 219033  Size: SH
  13. Inspect the plunge movement:
  14. Specification
    Plunge movement (approx.): 8.5 mm (0.33 in)

  15. If no plunge movement can be achieved, perform the following steps:
  16. • Disassemble the joint.
    • Repeat the assembly procedure until plunge movement can be achieved.

GKN Drive Axle Assembly

Tools Required

J 35566 Service Boot Clamp Pliers

  1. Remove the old silicone sealing bead from the dust shield caps and the outer constant velocity joint surfaces.
  2. Clean the dust shield cap and outer constant velocity joint surfaces.
  3. Install the drive axle boot onto the drive axle shaft.
  4. Install the dust shield cap onto the drive axle shaft.
  5. Important: The joint inner race should take the pressing load during the next step.

  6. Press the outer constant velocity joint onto the drive axle shaft:
  7. 5.1. Point the inner race identifying step toward the shaft shoulders.
    5.2. Point the outer race identifying channel away from the shaft.

    Object Number: 219037  Size: SH
  8. Install a new drive axle retaining ring (1).

  9. Object Number: 219038  Size: SH
  10. Apply a 2 mm bead of RTV to both cap surfaces.
  11. Allow the RTV to cure for about one hour.
  12. Pack the inside section of the joint and boot with 40 g of grease.
  13. Pack the outside section of the joint with 20 g of grease.
  14. Position the inner/outer dust shield caps (1) onto the outer constant velocity joint, aligning all bolt holes.
  15. Using a soft-faced mallet, tap the dust shields into place on the joint.

  16. Object Number: 219039  Size: SH
  17. Locate the ends of the boot into the boot groove on the dust shield cap and shaft, if removed.
  18. Move the small end of the boot up the shaft to the joint in order to purge any air pressure in the boots and work out any dimples before applying new clamps.

  19. Object Number: 219042  Size: SH
  20. Position a small clamp over the small end of the boot at the drive axle shaft.
  21. Using the J 35566 , crimps the clamp end.
  22. Position the large clamp over the large end of the boot at the drive axle shaft.
  23. Using the J 35566 , crimps the clamp end.

Installation Procedure

  1. Lubricate the drive axle spline with differential lubricant.
  2. Lubricate the seal surfaces with differential lubricant.
  3. Important: Use only enough force necessary to seat the drive axle into the rear axle differential.

  4. Use a rubber faced mallet to drive the outer end of the drive axle to install the drive axle into the differential bore.
  5. Position the other end of the drive axle into the wheel bearing hub inner flange.

  6. Object Number: 218877  Size: SH
  7. Use a ratchet to hold the J 42066 while installing the bolts to the drive axle flange.
  8. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Tighten
    Tighten the bolts to 50 N·m (37 lb ft) + 67 degrees.

  9. Remove the J 42066 from the wheel hub flange.
  10. Install the tire and wheel assembly. Refer to Wheel Installation .
  11. Lower the vehicle.