300, 300C & Magnum 2006-2008, Charger 2006-2008

Halfshafts

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CV-Joints



Overhaul
Inner
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove large boot clamp which retains inner tripod joint sealing boot to tripod joint housing and discard.
  4.  
  5. Remove small clamp which retains inner tripod joint sealing boot to interconnecting shaft and discard.
  6.  
  7. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft.
    WARNING
    When removing the tripod joint housing from the spider assembly, hold the bearings in place on the spider trunions to prevent the bearings from falling away.



    Click image to see an enlarged view

    Fig. Front halfshaft inner joint tripod housing (1), spider (2), boot (3)

  8.  
  9. Slide the tripod joint housing off the spider assembly and the interconnecting shaft.

    Click image to see an enlarged view

    Fig. Front shaft inner joint (1) shaft, (2) spider, (3) snapring

  10.  
  11. Remove snapring which retains spider assembly to interconnecting shaft. Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft.

    Click image to see an enlarged view

    Fig. Drive the spider from the shaft with a brass drift

  12.  
  13. Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift.
  14.  
  15. Slide sealing boot off interconnecting shaft.
  16.  
  17. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable.
  18.  

To assemble:

  1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then, slide the replacement inner tripod joint sealing boot onto the interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove on interconnecting shaft.

    Click image to see an enlarged view

    Fig. Install spider assembly (1) onto interconnecting shaft (2)

  2.  
  3. Install spider assembly onto interconnecting shaft. Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snapring.

    Click image to see an enlarged view

    Fig. Drive the spider (2) into place with a brass drift (4)

  4.  
  5. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift. Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft.
  6.  
  7. Install the spider assembly to interconnecting shaft retaining snapring into groove on end of interconnecting shaft. Be sure the snapring is fully seated into groove on interconnecting shaft.
  8.  
  9. Distribute 1 / 2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot.
  10.  
  11. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft.
  12.  
  13. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot.
  14.  
  15. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face.
    WARNING
    Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand.



    Click image to see an enlarged view

    Fig. Clamp type band tool. (1) clamp, (2) crimp completely closed, (3) shaft, boot (4)

  16.  
  17. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot.
    WARNING
    The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing sealing boot durability can be adversely affected.


    WARNING
    When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot cannot be used.

  18.  
  19. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly. When inserting trim stick between tripod housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing. If this is not done damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing not the hard plastic sealing boot and soft rubber insert.
  20.  
  21. With trim stick inserted between sealing boot and tripod joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint housing. This procedure will equalize the air pressure in the tripod joint, preventing premature sealing boot failure.
  22.  
  23. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recesses of the tripod housing.

    Click image to see an enlarged view

    Fig. Latching type boot clamp tool



    Click image to see an enlarged view

    Fig. Latching type clamp installed

  24.  
  25. Clamp sealing boot (3) onto tripod housing using clamp locking tool, Snap-On YA3050 (2) or an equivalent.
  26.  
  27. Place prongs of clamp locking tool in the holes of the clamp (1).
  28.  
  29. Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (2).
  30.  

Outer
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove large boot clamp retaining CV-joint sealing boot to CV-joint housing and discard.
  4.  
  5. Remove small clamp that retains outer CV-joint sealing boot to interconnecting shaft and discard.
  6.  
  7. Remove sealing boot from outer CV-joint housing and slide it down interconnecting shaft.

    Click image to see an enlarged view

    Fig. Outer CV-joint. (1) small clamp, (2) boot, (3) joint housing, (4) large clamp, (5) shaft

  8.  
  9. Wipe away grease to expose outer CV-joint and interconnecting shaft.

    Click image to see an enlarged view

    Fig. Outer CV-joint removal. (1) soft-faced hammer, (2) joint, (3) circlip

  10.  
  11. Remove outer CV-joint from interconnecting shaft using the following procedure:
    1. Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft.
    2.  
    3. Then, using a soft-faced hammer, sharply hit the end of the CV-joint housing to dislodge housing from internal circlip on interconnecting shaft.
    4.  
    5. Then slide outer CV-joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer.

      Click image to see an enlarged view

      Fig. Large circlip removal

    6.  

  12.  
  13. Remove large circlip from the interconnecting shaft before attempting to remove outer CV-joint sealing boot.
  14.  
  15. Slide failed sealing boot off interconnecting shaft.
  16.  
  17. Thoroughly clean and inspect outer CV-joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable.
  18.  

To assemble

  1. Slide new sealing boot to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer CV-joint assembly sealing boot onto the interconnecting shaft. Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft.
  2.  
  3. Align splines on interconnecting shaft with splines on cross of outer CV-joint assembly and start outer CV-joint onto interconnecting shaft.

    Click image to see an enlarged view

    Fig. Outer CV-joint installation

  4.  
  5. Install outer CV-joint assembly (3) onto interconnecting shaft by using a soft-faced hammer (1) and tapping end of stub axle (2), with nut (4) installed, until outer CV-joint is fully seated on interconnecting shaft.

    Click image to see an enlarged view

    Fig. Outer CV-joint assembly (3) must be installed on interconnecting shaft (1) until cross of outer CV-joint assembly (2) is seated against circlip on interconnecting shaft

  6.  
  7. Outer CV-joint assembly must be installed on interconnecting shaft until cross of outer CV-joint assembly is seated against circlip on interconnecting shaft.
  8.  
  9. Distribute 1 / 2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV-joint assembly housing. Put the remaining amount into the sealing boot.
  10.  
  11. Install outer CV-joint sealing boot to interconnecting shaft clamp evenly on sealing boot.
  12.  
  13. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face.
    WARNING
    Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand.

  14.  
  15. Position outer CV-joint sealing boot into its retaining groove on outer CV-joint housing. Install sealing boot to outer CV-joint retaining clamp evenly on sealing boot.
  16.  
  17. Clamp sealing boot onto outer CV-joint housing using Crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face.
  18.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support vehicle.
  4.  
  5. Remove wheel mounting nuts, then tire and wheel assembly.
  6.  
  7. While holding link ball joint stem from rotating, remove nut fastening stabilizer link to shock clevis bracket. Slide link ball joint stem from clevis bracket.
  8.  
  9. Remove nut and pinch bolt fastening clevis bracket to bottom of shock assembly.
  10.  
  11. Remove nut and bolt attaching shock clevis bracket to lower control arm.
  12.  
  13. Pull lower end of clevis bracket outward away from lower control arm bushing, then slide it off shock assembly. It may be necessary to use an appropriate prying tool to spread clamp area of clevis bracket allowing removal from shock assembly.
  14.  
  15. While a helper applies brakes to keep hub from rotating, remove hub nut from axle halfshaft.
    NOTE
    In some cases, it may be necessary to retract caliper piston in its bore a small amount in order to provide sufficient clearance between shoes and rotor to easily remove caliper from knuckle. This can usually be accomplished before mounting bolts are removed, by grasping rear of caliper and pulling outward working with guide pins, thus retracting piston. Never push on piston directly as it may get damaged.

  16.  
  17. Remove two bolts securing disc brake caliper and adapter to knuckle.
  18.  
  19. Remove disc brake caliper and adapter from knuckle as an assembly. Hang assembly out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this.
  20.  
  21. Remove any clips retaining brake rotor to wheel studs.
  22.  
  23. Slide brake rotor off hub and bearing.
    WARNING
    In following step, use care not to damage ball joint seal boot while sliding the puller into place past seal boot.

  24.  
  25. Separate upper ball joint stud from knuckle.
  26.  
  27. Remove tool.
  28.  
  29. Remove nut from end of upper ball joint stud.
  30.  
  31. Remove clip fastening wheel speed sensor to knuckle.

    Click image to see an enlarged view

    Fig. Right front halfshaft removal/installation

  32.  
  33. Disengage right halfshaft from axle and remove from vehicle.
  34.  
  35. Remove left halfshaft from vehicle.
  36.  

To install:

  1. Install left halfshaft assembly.

    Click image to see an enlarged view

    Fig. Axle seal installation

  2.  
  3. Using Tool C-4193-A, install new axle seal.
  4.  
  5. Install right halfshaft assembly.
    NOTE
    Before installing halfshafts into hub/bearing assemblies, ensure isolation washer is present on end of halfshaft. Inspect washer making sure it is not worn or damaged. Washer is bi-directional and can be installed in either direction on shaft.



    Click image to see an enlarged view

    Fig. Halfshaft isolation washer

  6.  
  7. Install halfshaft isolation washer.
  8.  
  9. Install halfshaft into hub/bearing assembly.
  10.  
  11. Loosely install halfshaft hub nut, and do not tighten at this time.
    WARNING
    It is important to tighten nut as described in following step to avoid damaging ball stud joint.

  12.  
  13. Place upper ball joint stud through hole in top of knuckle and install nut. Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 47 Nm plus 90° turn (35 ft. lbs. plus 90° turn) torque.
    NOTE
    Inspect brake shoes (pads) before installation.

  14.  
  15. Clean hub face to remove any dirt or corrosion where rotor mounts.
  16.  
  17. Install brake rotor over studs on hub and bearing.
  18.  
  19. Install disc brake caliper and adapter assembly over brake rotor.
  20.  
  21. Install mounting bolts securing caliper adapter to knuckle. Tighten bolts to 125 ft. lbs. (169 Nm).
  22.  
  23. Pull lower end of shock assembly outward, then slide clevis bracket onto lower end. Slide clevis bracket onto shock assembly until bracket contacts collar on shock housing.
  24.  
  25. Install pinch bolt and nut fastening clevis bracket to bottom of shock assembly. Install pinch bolt from rear. Do not tighten at this time.
  26.  
  27. Slide clevis bracket over bushing mounted in lower control arm.
  28.  
  29. Install bolt and nut attaching shock clevis bracket to lower control arm. Do not tighten at this time.
  30.  
  31. Tighten pinch bolt attaching clevis bracket to shock assembly to 45 ft. lbs. (61 Nm).
  32.  
  33. Slide stabilizer link ball joint stem into clevis bracket. Install nut fastening link to clevis bracket. Tighten nut by holding ball joint stud while turning nut. Tighten nut using crow foot wrench on torque wrench to 108 ft. lbs. (146 Nm).
  34.  
  35. Attach wheel speed sensor cable routing clip at knuckle.
  36.  
  37. Install hub nut on end of axle halfshaft. While a helper applies brakes to keep hub from turning, tighten hub nut to 157 ft. lbs. (213 Nm).
  38.  
  39. Install tire and wheel assembly. Tighten wheel mounting nuts to 110 ft. lbs. (150 Nm).
  40.  
  41. Lower vehicle.
    NOTE
    When tightening lower shock clevis mounting bolt, do not attempt rotating bolt. Bolt shaft is serrated. Turn nut only.

  42.  
  43. Tighten lower shock clevis bracket bolt nut to 128 ft. lbs. (174 Nm).
  44.  

 
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