Drive Axles Overhaul: Reassembly
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 1992 Saturn SL2, 1992 Saturn SL1, 1992 Saturn SL, 1992 Saturn SC, and 1991 Saturn SL2. However, it is still accessible from the selected car via links, so may be relevant.
- Inspect all tripod joint components for damage or wear. Replace tripod joint assembly as necessary. Clean drive axle shaft. Using a wire brush, clean any rust from drive axle shaft. Install, but DO NOT crimp, small boot clamp onto boot. Slide boot onto drive axle shaft, positioning boot neck in groove of drive axle shaft.
- Ensure small clamp is properly positioned on boot. Using Axle Boot Clamp Installer (SA9203C ), crimp boot clamp onto boot. Clamp ear gap should measure .085" (2.15 mm). If small boot clamp ear gap is not as specified, recrimp. Install spacer ring onto drive axle shaft past second groove on drive axle shaft.
- Install tripod joint, with counterbored surface facing end of shaft, onto drive axle shaft past shaft retaining ring groove on drive axle shaft. Using CV Joint Snap Ring Pliers (SA9198C
), install shaft retaining ring in groove of drive axle shaft. Slide tripod joint toward end of drive axle shaft, and reseat spacer ring in groove on drive axle shaft. Pack inside of boot and tripod joint housing with grease.NOTE: Tripod joint assembly must be installed with convolute retainer in position.
- Install convolute retainer, supplied with service kit, over boot. Install, but DO NOT
crimp, large boot clamp onto boot. Install tripod joint housing onto drive axle shaft and slide over tripod joint. Slide boot over outside of tripod joint housing, positioning lip of boot in groove of tripod joint housing.NOTE: Boot will be damaged if tripod joint assembly is not assembled to correct dimension.
- Ensure boot is not dimpled or stretched out of shape. Carefully reshape boot by hand as necessary. Measure length of assembledtripod joint assembly. Right tripod joint assembly should measure 8 5/8" (220 mm). Left tripod joint assembly should measure 11" (280 mm). Ensure large clamp is properly positioned on boot. Using Axle Boot Clamp Installer (SA9161C ), crimp boot clamp onto boot.
- Inspect all inner race joint components for damage or wear. Replace inner race joint assembly as necessary. Lubricate inner and outer race grooves with grease. Insert and rotate inner race into cage. Install cage and inner race into outer race with windows of cagealigned with lands of outer race.
- Install balls using a brass drift to gently rotate and position cage and inner race. Install race retaining ring into inner race. Pack inner race joint with grease.
- Install, but DO NOT crimp, small boot clamp onto boot. Slide boot onto drive axle shaft, positioning boot neck in groove of drive axle shaft. Ensure small clamp is properly positioned on boot. Using Axle Boot Clamp Installer (SA9203C ), crimp boot clamp onto boot. Clamp ear gap should measure .085" (2.15 mm). If small boot clamp ear gap is not as specified, recrimp.
- Pack inside of boot and inner race joint housing with grease. Install, but DO NOT crimp, large boot clamp onto boot. Install inner race joint with race retaining ring side of inner race facing drive axle shaft. Push inner race joint assembly onto drive axle shaft until race retaining ring is seated in groove on drive axle shaft.
- Slide boot over outside of inner race joint housing, positioning lip of boot in groove of inner race joint housing. Ensure boot is not dimpled or stretched out of shape. Carefully reshape boot by hand as necessary. Ensure large clamp is properly positioned on boot.
- Using Axle Boot Clamp Installer (SA9203C ), crimp boot clamp onto boot. Clamp ear gap should measure .102" (2.60 mm). If large boot clamp ear gap is not as specified, recrimp. Position NEW deflector ring onto outer race. Using Axle Deflector Ring Installer (SA1960C ) and a M20 x 1.0 nut, tighten nut until deflector ring bottoms against shoulder of outer race.