I have an '02 Magnum 325 4x4 and I recently tore my struts down to grease the upper bushings. In process I must have pulled the axle shaft out of the left CV which fubar'd the shaft and disassembled the CV for me.

After cleaning everything up, the CV appears to be in perfect shape, save for is state of disassembly. No scoring, pitting, broken peices and the cage and inner race all rotate inside each other freely.

I already have to buy the axle shaft and U-Joint but would like to only spend $150 on that than $250 on that AND the CV joint.

Can anyone help me reassemble my CV? I went to a local dealer and their service guys couldn't do it because none of their manuals had any material on it...yeah.

I know it can be done because it WAS together and I DID get it apart.

PLEASE help me save $100!

Thanks a ton!!

 

Just start by putting in 1 ball at a time and then another and another..you have to rotate the cage just perfect so that it will all slide down in at the last ball..it's a PITA but it can be done as I've done it before!

 

CV Joint Rebuilding Instructions

Once you’ve removed the outer cv joint from the axle shaft place it in a vise with the splined end facing down.

Make note of the position of the cage and race in the housing to insure that you reassemble it back the same way. Now use a small tack hammer or a regular hammer with a punch or screw driver to tap the inner race in between the ***** down inside the joint. This will force the cage up to one side exposing the ball. Use a screw driver to pop the ball from the cage window. Repeat this process all the way around the inner race until all of the ***** are removed. Now turn the race and cage assembly side ways in the housing with the cage window facing upward.
Line the two cage windows that are going to be on the sides across from each other with the area in between the ball tracks (some cages have 1 or 2 cage windows larger than the others make sure to line these windows up to be on the side) of the housing and pull up. This should free the assembly from the cv joint housing. Once you have the race and cage free from the housing turn the race side ways in the cage and line up the area in between the ball tracks with the window openings and push one side into the window.

This will allow you to pull up on the race and free it from the cage. Now clean everything thoroughly and inspect the parts for any wear dimples or pitting. If you drop the cage on a hard surface it should make a pinging sound, if not look closely for a crack because I’m sure you will find one.

To reassemble the cv joint place the race back into the cage in the same manner as it was removed. Then place the cage and race back into the cv joint housing in the same way it was removed. Turn them both to make sure that you have them facing up in the correct direction as they were upon removal. Now place one ball into the cage window and tap lightly on the cage while holding the race to keep it from moving out of position to make contact with the ball.

Once the ball is down into the track tap lightly on the cage and race toward the side of that ball to expose the next window and repeat the process until all of the ***** are installed. Now take your shaft (with the clip removed and place it in the cv joint and rotate it around (no more than a 30 angle) to check for the smoothness of operation. Then twist the shaft from side to side to check for looseness. It may have a little play just nothing excessive. Now take your grease packet and cut the corner of the bag to make it like a bakers bag and press it tightly into the hole were the shaft will go. Squeeze until you see grease come up around the ***** then set the packet aside for the next procedure. Now take the shaft (with the clip installed) and line up the splines of the shaft with the ones on the cv joint and press downward. You’ll want to use a screwdriver to push the clip inward while pressing down to get it centered. Now give the shaft a light tap with a soft hammer and the shaft should slide in easily until you feel the clip catch. It’s a good idea to give it a good yank to make sure it seated. Then take the remaining grease and make a bead around the top of the joint (ice cream cone shaped up toward the boot). Now slide the boot down and tighten the large clamp. Before you tighten the small clamp put a screw driver in between the shaft and the boot to allow any trapped air to escape then remove it and install the small clamp. Now you’re Ready to put the axle back into the vehicle. If you have any questions or concern you can pm me for technical assistance.
Thanks,
Danny
thecvman

Disclaimer: (the lawyers make me do this)
I offer these installation instruction based upon my experiences and knowledge of this procedure. I can not be held responsible for any damage or liabilities that may occur. These instructions are offered as a suggestion and not intended to offer guaranteed results. If you under take this task it will be at your own risk and no responsibility of CV Restoration or anyone representing them. If you disagree with these terms then I recommend that you refer the procedure to a trained responsible party.

 

Ahhh! my hero!

Thanks a ton man!

Got it assembled and now I need to order the axle shaft and u-joint.

Also, can the CV grease that is specified be substituted for anything else? I'd rather be able to pack it full with as much as I please than buy a bunch of those packets at ~$5 each.