05 Sunfire Manual Transmission CV Shaft seal problems.

04-18-2015, 12:54 PM
I am trying to install a new seal for the passenger CV shaft on my 05 sunfire manual transmission.

I have the car up high on jack stands and tried using a large socket to fit around the metal outer ring however it doesn't want to fit into the housing.

I can tap one side into the housing but the other side won't budge and become flush .

any suggestions ? :runaround::runaround::crying:

Tech II
04-18-2015, 10:56 PM
Usually the problem is removal, not installation.......

Does the axle easily come out?

Check the C-clip for burrs........try lubricating it with petroleum jelly......then engage the splines in the tranny, and give it a good push...should pop right in...if it doesn't, rotate it and push again....

04-19-2015, 11:31 AM
I got the old axle out already. What i am trouble with is the seal. I got the old seal out because it had a dent in it. Getting the new seal in is the challenge. It will start to go in but then it gets stuck. I have a heavy 2 1/4" inch tool to go around the outer gasket ring trying to tap it in.

04-19-2015, 03:14 PM
Just to make sure we're on the same page, this is about the boot around the spider gears on the joint, right? Assuming it is, ideally you want to use a new c clip.
Fasteners like c clips, snaprings, cotter pins, etc. get worn out after being installed, doing their job, and being removed. If reinstalled, that old c clip could fail, possibly leading to a whole new set of problems.

Tech II
04-19-2015, 05:53 PM
OK, I misread your post......

Yes, the new seal can cock to one side if you don't drive it in straight.....if you have a large socket that fits around the outer edge, you will cock the edge of the socket so you only make contact with the side that is sticking out, and give that side a good whack, to drive that side in...

04-20-2015, 06:44 AM
I got in and finally assembled yesterday. I stuck the gasket in the freezer over night, then on the opposite side, I heated up the housing for about a minute or so with a propane torch and used a big giant socket to bang it into place.

i had to get my boy to hold the socket so i get a good swing straight at the gasket.

Add your comment to this topic!