Axle Shafts: Reassembly

Inspect all tripot joint components for damage or wear. Replace tripot joint assembly as necessary. Using a wire brush, clean any rust from axle shaft. Install, but DO NOT crimp, small boot clamp onto boot. Slide boot onto axle shaft, positioning boot neck into groove of axle shaft.
Ensure small clamp is properly positioned onto 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 axle shaft, past second groove.
Install tripot joint onto axle shaft, past retaining ring groove. Using snap ring pliers, install shaft retaining ring into groove of axle shaft. Slide tripot joint toward end of axle shaft, and reseat spacer ring into groove on axle shaft. Pack inside of boot and tripot joint housing with grease.

NOTE: Tripot 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 tripot joint housing onto axle shaft and slide over tripot joint. Slide boot over outside of tripot joint housing, positioning lip of boot in groove of tripot joint housing.
Ensure boot is not dimpled or stretched out of shape. Carefully reshape boot by hand as necessary. Measure length of assembled tripot joint assembly, between inner edge of small boot clamp and outer end of tripot joint housing. Right tripot joint assembly should measure 8 5/8" (220 mm). Left tripot joint assembly should measure 11" (280 mm). Ensure large clamp is properly positioned on boot. Using axle boot clamp installer, crimp boot clamp onto boot.
If dynamic damper was removed, measure 7.95" (202 mm) from outboard end of axle shaft. Mark this location with a piece of masking tape. See Fig 1 . Tightly wrap axle shaft splines with vinyl tape. Lubricate shaft with liquid detergent. Tap dynamic damper onto shaft, aligning inboard edge of damper with edge of masking tape. Remove masking tape and vinyl tape from axle shaft. Crimp damper retaining clamp.

Fig 1: Installing Dynamic Damper Onto Axle Shaft
Courtesy of GENERAL MOTORS CORP
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 onto outer race with windows of cage aligned with lands of outer race.
Install balls using a brass drift to gently rotate and position cage and inner race. Install race retaining ring onto inner race. Pack inner race joint with grease.
Install, but DO NOT crimp, small boot clamp onto NEW boot. Slide boot onto axle shaft, positioning boot neck in groove of axle shaft. Ensure small clamp is properly positioned onto boot. Using axle boot clamp installer, 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 axle shaft. Push inner race joint assembly onto axle shaft until race retaining ring is seated into groove on axle shaft.
Slide boot over outside of inner race joint housing, positioning lip of boot into 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, 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. If removed, position NEW deflector ring onto outer race. Using Axle Deflector Ring Installer (J44280-2), install deflector ring and bottom out against tripot housing.