How to replace the outer CV Joint and seal on 2004 Chevrolet Impala?

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Accepted Answer

To replace the wheel drive shaft outer joint and seal you should start by removing the large seal retaining clamp from the cv using a side cutter and discard it. Do not cut the wheel drive shaft inboard seal to avoid destruction of the sealing face. Take out and discard to one side the swage ring using a hand grinder to cut through the swage ring so as to get rid of it and then take out the halfshaft outboard seal off from the CV Joint outer race at the big end and slide the outboard seal as far away as possible from the joint along the halfshaft bar. Next, clean the grease off the CV Joint inner race, and spread ears on the race retaining ring, using snap ring pliers (J 8059). Disassemble the CV Joint assembly from the half shaft bar and throw out the old outboard seal. Tap and tilt the CV Joint cage using a brass drift to pop off the six chrome alloy balls, repeating the process until all six have been removed. If any of the parts show signs of wear or if they have cracks or any damage, replace those damaged parts thoroughly clean the entire cv with the cleaning solvent as well as the outer and inner race assemblies, bottle brush, referee the chrome alloy balls and then dry everything up. Clean the halfshaft bar with a wire brush around the rust in the seal mounting area. To assemble, place the swage ring onto the neck of the outboard seal unaswaged, slide the outboard seal over the halfshaft bar and align it into the seal groove. Swage the ring with drive axle swage ring clamp (J 41048) by aligning and tightening the bolts until they are snug and check for deformities and re swage if necessary. Squeeze light grease on the groove of the ball inside & outside race, then put the inner race in cage and put it properly. Put in the cage and inner race, slide the chrome balls into them and fill the CV Joint with grease. Push the CV Joint onto the halfshaft bar and make sure that the retaining ring is seated and the outboard seal is shaped properly. Last, slide the wide section of the outboard seal with large seal retaining clamp set onto the CV Joint outer race and crimp the clamp using drive axle seal clamp pliers (J 35910) at 174 nm (130 ft.lbs.) with the level checked on the clamp ear, doing this until it measures at 1.9 mm (5/64 inch).

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