How to replace Halfshafts on 2006 Chevrolet Cobalt ?

Halfshafts

CV-Boots Inspection

1. Before servicing the vehicle, refer to the Precautions Section.
2. Check the driveshaft boots for damage and deterioration.
   
   
   Raise front of vehicle

   Rotate axle and inspect for cracked or ripped CV boot material on inner and outer CV joints on both sides of vehicle

   Inspect for excessive grease deposits on or around the CV boot
3. Replace boot if damaged or deteriorated.

CV-Joints

Overhaul
Inner
Delphi Type

WARNING

With removal of the wheel driveshaft for any reason, the transaxle sealing surface (the tripot male/female shank of the wheel driveshaft) should be inspected for corrosion. If corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a rotation motion. Do not clean with an oscillating motion. Transaxle fluid may be used to clean off any remaining debris. The surface should be wiped dry and the wheel driveshaft reinstalled free of any buildup.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Use a hand grinder in order to cut through the swage ring. Do not damage the tripot housing (1).
3. Remove the large boot retaining clamp from the tripot joint with side cutter.
4. Dispose of the large boot retaining clamp.
   
   WARNING

   Do not cut through the halfshaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.
   
   
   
   
   

   

   Fig. Delphi type inner joint
5. Separate the wheel driveshaft inboard boot from the trilobal tripot bushing (3) at the large diameter.
6. Slide the boot (4) away from the joint along the shaft.
7. Remove the housing (1) from the tripot joint spider (2) and the shaft.
8. Remove and discard the trilobal tripot bushing (3) from the housing (1).
9. Remove and discard the lower spacer ring from the groove on the shaft.
10. Slide tripot joint spider assembly off of the shaft.
11. If present, remove and discard the second spacer ring from the shaft.
12. Clean the following items with cleaning solvent:
    
    
    The tripot balls

    The needle rollers

    The housing
13. Remove all traces of old grease and any contaminates. Dry all parts.
14. Inspect the parts for damage or wear.

To assemble:

1. Place the new small boot clamp onto the small end of the joint boot. Slide the joint boot and the small boot clamp onto the shaft.
2. Position the small end of the joint boot into the joint boot groove on the shaft.
3. Mount tool DT-47732 in a vise and proceed as follows:
   1. Position the inboard end of the wheel driveshaft assembly in tool DT-47732.
   2. Align the top of boot neck on the bottom die using the indicator.
   3. Place the top half of tool DT-47732 on the lower half of tool.
   4. Before proceeding, ensure there are no pinch points on the wheel driveshaft inboard boot. This could cause damage to the inboard boot.
   5. Insert the bolts.
   6. Tighten the bolts by hand until snug.
4. Align the following items:
   
   
   The inboard boot 

   The shaft boot grooves

   The swage ring 
5. Tighten each bolt of DT-47732 180° at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
6. If equipped, install the spacer ring on the shaft in groove.
7. Slide the tripot joint spider assembly toward the spacer ring as far as it will go on the shaft.
8. Install the shaft retaining ring in the groove of the shaft.
9. 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.
   
   NOTE

   Ensure the trilobal tripot bushing is flush with the face of the housing.
10. Install the trilobal tripot bushing to housing.
11. Position the larger new boot retaining clamp on the shaft inboard boot.
12. Slide the housing over the tripot joint spider assembly on the shaft.
13. Slide the large diameter of the inboard boot, with the larger clamp in place, over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.
    
    WARNING

    The inboard boot must not be dimpled, stretched out or out of shape in any way. If the inboard boot is not shaped correctly, 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. Shape the inboard boot properly by hand. Remove the tool.
    
    
    
    
    

    

    Fig. Joint assembly measurement
14. Position the joint assembly at dimension  a equals 4.21 inches (107mm).
15. Align the following items while latching:
    
    
    The seal 

    The tripot housing 

    The large seal retaining clamp
16. Crimp the seal retaining clamp with tool J 35910 to 130 ft. lbs. (176 Nm). Add the breaker bar and the torque wrench if necessary.
17. Verify dimension  a equals 0.085 inch (2.15mm).
18. Fully stroke the joint several times to disperse the grease.

Gkn Type

WARNING

Do not cut through the halfshaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

Fig. GKN inner joint

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the swage ring from the shaft using a hand grinder to cut through the ring, taking care not to damage the shaft.
3. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp.
4. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter.
5. Slide the seal away from the joint along the shaft.
6. Remove the housing (1) from the tripot joint spider and the shaft (2).
7. Remove the spacer ring, spider assembly, spacer ring, and tripot boot. Discard the boot and rings.
8. Clean the shaft. Use a wire brush in order to remove any rust in the boot mounting area (grooves).
9. Inspect the needle rollers, needle bearings, and trunion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit.

To assemble:

Fig. Swage ring installation-GKN inner joint

1. Place the new small swage ring (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the small swage ring (2) onto the shaft.
2. Position the small end of the joint seal (1) into the joint seal groove (3) on the shaft.
   
   
   

   

   Fig. Using tool J41048 or DT-47732
3. Mount tool J 41048 in a vise and proceed as follows:
   1. Position the inboard end (1) of the halfshaft assembly in tool J 41048.
   2. Align the top of seal neck on the bottom die using the indicator.
   3. Place the top half of the J 41048 on the lower half.
   4. Before proceeding, ensure there are no pinch points on the halfshaft inboard seal. This could cause damage to the inboard seal.
   5. Insert the bolts (2).
   6. Tighten the bolts by hand until snug.
      
      
      

      

      Fig. Seal and swage ring alignment
4. Align the following items:
   
   
   The inboard seal (1)

   The shaft

   The swage ring (2)
5. Tighten each bolt of J 41048 180° at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
6. Install the spacer ring into the groove of the shaft.
7. Slide the tripot joint spider assembly toward the spacer ring as far as it will go on the shaft.
8. Install the spacer ring into the groove of the shaft.
9. Place approximately half of the grease from the service kit in the inboard seal. Use the remainder of the grease to repack the housing.
   
   NOTE

   Ensure the trilobal tripot bushing is flush with the face of the housing.
10. Install the new trilobal tripot bushing to housing.
11. Position the larger new seal retaining clamp on the inboard seal.
12. Slide the housing over the tripot joint spider assembly on the shaft.
13. Slide the large diameter of the inboard seal, with the larger clamp in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
    
    NOTE

    The inboard seal must not be dimpled, stretched out or out of shape in any way. If the inboard seal is not shaped correctly, carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Shape the inboard seal properly by hand.
14. Remove the tool.
15. Position the joint assembly at the proper vehicle dimension: 3 ³ / ₄ inches (95mm).
16. Align the following items while latching:
    
    
    The inboard seal

    The tripot housing 

    The large seal retaining clamp 
    
    

    

    

    Fig. Crimping the retaining clamp
17. Crimp the seal retaining clamp with J 35910, or equivalent, to 130 ft. lbs. (176 Nm). Add the breaker bar (5) and the torque wrench (4) to the tool, if necessary.
18. Check the gap dimension (a) on the clamp ear. If gap dimension is larger than shown, continue tightening until gap dimension of 0.102 inch (2.6mm) is reached.
19. Fully stroke the joint several times to disperse the grease.

Outer
Delphi Type

NOTE

Due to the helical splines on the shaft, disassembly and assembly of the joints will be difficult.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the large seal retaining clamp.
3. Remove the small seal retaining clamp from the shaft with a side cutter and discard.
4. Separate the CV joint seal from the CV joint race at the large diameter.
5. Slide the seal away from the joint along the shaft.
6. Wipe the grease from the face of the CV joint inner race.
   
   
   

   

   Fig. Reference marking the shaft-Delphi type outer joint
7. Before removing the CV joint assembly from the half shaft bar, perform the following procedure:
   1. Choose a reference mark (B) on the shaft.
   2. Measure the distance between the reference mark (B) and the face of the CV joint inner race. Make a note of this measurement (A).
   3. Mark as a reference the inboard side, toward the center of the half shaft bar, of the CV joint inner race.
   4. Inspect the CV joint inner race/shaft interface for the presence of a retaining ring. If present, remove the retaining ring using.
8. Clamp the shaft into a vise.
9. Attach a slide hammer to the threaded area of the outer race.
10. Remove the CV joint from the shaft.
    
    NOTE

    Never reuse the retaining ring.
11. Remove the retaining ring from the shaft. Discard the retaining ring.
12. Remove the CV joint seal from the shaft.
13. Place a brass drift against the CV joint cage.
14. Tap gently on the brass drift with a hammer in order to tilt the cage.
15. Remove the first chrome alloy ball when the CV joint cage tilts.
16. Tilt the CV joint cage in the opposite direction to remove the opposing chrome alloy ball.
17. Repeat this process to remove all 6 balls.
18. Pivot the CV joint cage and the inner race 90° to the centerline of the outer race. At the same time, align the cage windows with the lands of the outer race.
19. Lift out the cage and the inner race.
20. Remove the inner race from the cage by rotating the inner race upward.
21. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
22. Dry all the parts.
23. Check the CV joint assembly for unusual wear, cracks, or other damage.
24. Replace any damaged parts.
25. Clean the shaft. Use a wire brush to remove any rust in the seal mounting area (grooves).

To assemble:

1. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race.
2. Hold the inner race 90° to the centerline of the cage with the lands of the inner race aligned with the windows of cage.
3. Insert the inner race into the cage.
4. Hold the cage and the inner race 90° to the centerline of the outer race. Align the cage windows with the lands of the outer race.
   
   NOTE

   Ensure that the inner race is oriented the same as prior to disassembly. Use the reference mark placed earlier.
5. Install the cage and the inner race into outer race.
6. Place a brass drift against the CV joint cage.
7. Tap gently on the brass drift with a hammer in order to tilt the cage.
8. Install the first chrome alloy ball when the CV joint cage tilts.
9. Repeat this process to install all 6 balls.
10. Pack the CV joint with half of the grease supplied in the service kit.
11. Install the new swage ring on the neck of the seal. Do not crimp.
12. Clean the shaft. Use a wire brush to remove any rust in the seal mounting area (grooves).
13. Slide the CV joint seal onto the shaft. Expose the reference mark by sliding the CV joint seal up the shaft toward the tripot end.
14. Position the large seal retaining clamp around the joint seal.
15. Place the new retaining ring onto the shaft.
16. While supporting the tripot assembly, place the wheel drive shaft assembly onto the arbor press with the CV assembly under the press head.
17. Lower the arbor press head onto the CV joint assembly until the press cannot move any further. This ensures that the retaining ring engages in the inner race. Do not exceed 4,000 lb. press load during assembly.
18. Remove the wheel drive shaft assembly from the arbor press.
19. Measure the distance between the reference mark on the shaft (B) and the face of the CV joint inner race.
20. Compare the mark with the measurement made before disassembly.
21. Repeat the previous 4 steps if the current measurement does not match the measurement made before disassembly.
22. Place the new swage ring onto the small end of the joint boot. Slide the boot and the swage ring onto the half shaft bar.
23. Position the small end of the boot into the boot groove on the half shaft bar.
24. Mount tool DT-47732 in a vise and proceed as follows:
    1. Position the outboard end of the wheel drive shaft assembly in tool.
    2. Align the top of boot neck on the bottom die using the indicator.
    3. Place the top half of the DT-47732 on the lower half of the DT-47732.
    4. Before proceeding, ensure there are no pinch points on the boot. This could cause damage to the boot.
    5. Insert the bolts.
    6. Tighten the bolts by hand until snug.
25. Align the following items:
    
    
    The shaft outboard boot

    The shaft boot grooves

    The swage ring
26. Tighten each bolt of DT-47732 180° at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
27. Place the remaining grease from the service kit inside the seal.
    
    
    

    

    Fig. Measure approximately 17.5 mm (11/16 in.) up from the bottom edge of the CV outer joint assembly-Delphi type outer joint
28. Mount DT-47732 in a vise and proceed as follows: Measure approximately 17.5 mm ( ¹¹ / ₁₆ in.) up from the bottom edge of the CV outer joint assembly.
29. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of CV joint.
    
    WARNING

    The CV joint seal must not be dimpled, stretched or out of shape in any way. If seal is not shaped correctly, equalize pressure in the seal and shape the seal properly by hand.
30. Locate the seal lip to the ridge of the CV outer joint assembly as measured in the previous step.
31. Crimp seal retaining clamp with tool J 35910, a breaker bar, and a torque wrench. Tighten seal retaining clamp to 130 ft. lbs. (176 Nm).
32. Check the gap dimension. Continue tightening until the correct gap dimension is reached. Dimension  a equals 0.091 inch (2.3mm).

Gkn Type

Fig. GKN outer joint

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp.
3. Use a hand grinder to cut through the swage ring in order to remove the swage ring.
4. Separate the outboard seal from CV joint outer race (1) at large diameter.
5. Slide the seal (5) away from joint along shaft (4).
6. Wipe the grease from the face of the CV joint inner race.
7. Spread the ears on the race retaining ring.
8. Remove the CV joint assembly from the shaft.
9. Remove the outboard seal (5) from the shaft.
10. Discard the old outboard seal.
11. Place a brass drift against the CV joint cage.
12. Tap gently on the brass drift with a hammer in order to tilt the cage.
13. Remove the first chrome alloy ball when the CV joint cage tilts.
14. Tilt the CV joint cage in the opposite direction to remove the opposing chrome alloy ball.
15. Repeat this process to remove all 6 of the balls.
16. Pivot the CV joint cage and the inner race 90° to the center line of the outer race. At the same time, align the cage windows with the lands of the outer race.
17. Lift out the cage and the inner race.
18. Remove the inner race from the cage by rotating the inner race upward.
19. Clean the all items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates.
20. Dry all the parts.
21. Check the CV joint assembly for the following items wear and damage.
22. Replace any damaged parts.
23. Clean the shaft. Use a wire brush to remove any rust in the grooves of the seal mounting area.

To assemble:

1. Install the new swage ring on the neck of the outboard seal. Do not swage.
2. Slide the outboard seal onto the shaft and position the neck of the outboard seal in the seal groove on the shaft. The largest groove below the sight groove on the shaft is the seal groove.
3. The swage ring is swaged using tool J 41048 by the following method:
   1. Position the outboard end of the wheel drive shaft assembly in J 41048.
   2. Align the swage ring.
   3. Place the top half of J 41048 on the lower half of J 41048.
      
      NOTE

      Align the following items during this procedure:
      
      
      
      
      The outboard seal

      The shaft

      The swage ring
   4. Insert the bolts and tighten by hand until snug. Tighten each bolt 180° at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed.
4. Loosen the bolts and separate the dies.
5. Check swaged ring for any lip deformities. If present, place the ring back into the J 41048 making sure the ring covers the whole swaging area. Then re-swage the ring.
6. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race.
7. Hold the inner race 90° to centerline of cage with the lands of the inner race aligned with the windows of the cage and insert the inner race into the cage.
8. Hold the cage and the inner race 90° to centerline of the outer race and align the cage windows with the lands of the outer race.
   
   NOTE

   Verify that the retaining ring side of the inner race faces the shaft.
9. Place the cage and the inner race into the outer race.
10. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball.
11. Repeat this process until all 6 balls are in place.
12. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.
13. Push the CV joint onto the shaft until the retaining ring is seated in the groove on the shaft.
    
    NOTE

    The outboard seal must not be dimpled, stretched or out of shape in any way. If the outboard seal is not shaped correctly, equalize the pressure in the outboard seal and shape the seal properly by hand.
14. Slide large diameter of the outboard seal with the large seal retaining clamp in place over the outside of the CV joint outer race and locate the seal lip in the groove on the CV joint outer race.
15. Crimp the seal retaining clamp using J 35910. Crimp the clamp to 130 ft. lbs. (176 Nm).
16. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Dimension a equals ³ / ₃₂ inch (2.3mm).

Removal & Installation

Outer Shaft

1. Before servicing the vehicle, refer to the Precautions Section.
2. Raise and support the vehicle.
3. Remove the tire and wheel assembly.
4. Remove the halfshaft nut. Insert a drift or a flat-bladed tool into the caliper and the rotor to prevent the rotor from turning.
5. Carefully loosen the halfshaft splines from the wheel bearing/hub assembly using a wood block and a hammer. The nut can be partially reinstalled to protect the threads.
   
   NOTE

   Be sure that the wheel speed sensor wiring harness is repositioned away from the ball joint after disconnecting the electrical connector from the sensor.
6. Disconnect the ball joint from the steering knuckle.
7. Separate the halfshaft from the wheel bearing/hub assembly, then, support the shaft assembly.
   
   
   

   

   Fig. Assemble tools J 45341 and J-2619-A, or equivalents, to the halfshaft inner tripot housing assembly
8. Assemble tools J 45341 and J-2619-A, or equivalents, to the halfshaft inner tripot housing assembly.
9. Separate the halfshaft from the transaxle, then, remove the shaft assembly.
10. Inspect the transaxle output shaft seal for damage and/or contamination and replace if necessary.

To install:

Fig. Install tool J 44394 into the transaxle output shaft seal

1. Install tool J 44394 into the transaxle output shaft seal.
2. Install the halfshaft into the transaxle until the drive shaft splines are past the seal, remove the tool, then fully install the drive shaft.
3. Verify that the halfshaft is properly engaged:
   1. Grasp the inner tripod housing and pull the inner housing outward. Do NOT pull on the wheel drive axle shaft.
   2. The halfshaft will remain firmly in place when properly engaged.
4. Install the halfshaft to the wheel bearing/hub assembly.
5. Connect the ball joint to the steering knuckle.
6. Install the halfshaft nut to the halfshaft assembly. Tighten the nut to 155 ft. lbs. (210 Nm).
7. Install the tire and wheel assembly.
8. Lower the vehicle.
9. Inspect the transaxle fluid level.

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