Volt

Front Wheel Drive Shaft Outer Joint Boot Replacement

Special Tools

For equivalent regional tool, refer to Special Tools .

1. Remove the wheel drive shaft from the vehicle. Refer to Front Wheel Drive Shaft Replacement .



2. Install the drive axle shaft in a soft-jawed vice.




Caution: 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.

3. Use a flat-bladed tool, remove the boot clamp (2) from the constant velocity (CV) joint (1) and the boot (3).
4. Using a pair of side cutters, remove the boot clamp (4) from the boot (3) and the wheel drive shaft (5).
5. Discard the boot clamps (2) and (4). Use only NEW clamps.




Warning: Use of eye goggles is necessary to prevent personal injury.

6. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. DISCARD the retaining clamp.
7. Separate the boot (4) from CV joint outer race (1) at large diameter.
8. Slide the boot (4) away from joint along half shaft bar (5).
9. Wipe the grease from the face of the CV joint inner race (2).
10. Spread the ears on the race retaining ring (3) with GE-396 pliers (6).



11. Using a block of wood and a hammer, remove the CV joint (2) from the half shaft bar (1).



12. Remove and DISCARD the boot (1) from the half shaft bar (2).

Note: If there is any sign of damage or excessive wear, replace the wheel drive shaft as an assembly. There are no service parts available for the outer joint assembly.

13. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.

•	The inner and outer race assemblies

•	The CV joint cage

•	The chrome alloy balls

14. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).

1. Position the boot and the clamp (1) on the half shaft bar (2).



2. Ensure that the boot (1) is properly seated in the grooved (2) half shaft bar (3).
3. Place approximately 95 grams (3.4 ounces) of lubricant inside the outboard boot and pack the CV joint with the remaining lubricant. Refer to Adhesives, Fluids, Lubricants, and Sealers .



4. Using a block of wood and a hammer, install the CV joint (1) on the half shaft bar.



5. Install the boot clamp (2) on the CV joint housing (1).




Note: Ensure that the boot clamp is properly positioned around the entire circumference of the boot.

6. Using the DT-35910 pliers with a breaker bar and a ratchet spanner (1), tighten the boot clamp (2) until the gap (3) in the boot clamp measure 1.6 mm (0.06 in).



7. Using the DT-35910 pliers (3), breaker bar (5), and the torque spanner or ratchet spanner (4), tighten the boot clamp (1) until the gap (6) in the boot clamp measure 2.0 mm (0.08 in).
8. Distribute the lubricant within the outer CV joint by moving it in a circular motion at least four to five times.
9. Remove the wheel drive shaft from the bench vice.
10. Install the wheel drive shaft assembly. Refer to Front Wheel Drive Shaft Replacement .