Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Halfshafts

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CV-Joints



Inspection
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Check the driveshaft boots for damage and deterioration.

    Raise the front of the vehicle
     
    Rotate the axle and inspect for cracked or ripped CV boot material on the inner and outer CV-joints. Repeat this step on both sides of vehicle.
     
    Inspect for excessive grease deposits on or around the CV boot
     

  4.  
  5. Replace the boot if it is damaged or deteriorated.
  6.  

Overhaul

Servicing the CV-joints is limited to replacing the CV boot. Further servicing of the CV-joints is not possible and the CV-joint must be replaced if worn or damaged.

Inner Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Remove the halfshaft.
  6.  
  7. Remove the large and small boot retaining clamps.
  8.  
  9. Slide the boot down the shaft away from the tri-pod housing.
    NOTE
    When separating the spider joint from the tri-pod joint housing, hold the rollers in place on the trunnions to prevent the rollers and needle bearings from falling away.

  10.  
  11. Carefully slide the shaft/spider assembly from the tri-pod housing.
  12.  
  13. Remove the spider assembly-to-shaft snap ring; then, slide the spider assembly off the shaft.
    WARNING
    If necessary, tap the spider assembly off the shaft using a brass drift; be careful not to hit the outer bearings.

  14.  
  15. Slide the boot off the shaft.
  16.  
  17. Thoroughly inspect all parts for signs of excessive wear. If necessary, replace the halfshaft.
    NOTE
    Component parts are not serviceable and must be replaced as an assembly.



    Click image to see an enlarged view

    Fig. View of a typical halfshaft assembly



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    Fig. View of the halfshaft inner tri-pod joint and snap ring



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    Fig. View of the halfshaft boot and shaft



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    Fig. Securing the halfshaft boot clamp



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    Fig. Tightening the low profile boot clamp-Silicone rubber Tri-pod boot



    Click image to see an enlarged view

    Fig. Secure the low profile boot clamp-Silicone rubber Tri-pod boot

  18.  

To install:


WARNING
The Tri-pod sealing boots are made of 2 different types of material; silicon rubber (high temperature) which is soft and pliable or Hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot made of the correct material.

  1. Slide the inner tri-pod boot clamp and boot onto the shaft. Then, position the boot so that only the thinnest (sight) groove is visible on the shaft.
  2.  
  3. Install the spider assembly onto the shaft just far enough so that the snap ring can be installed.
    WARNING
    If necessary, tap the spider assembly onto the shaft using a brass drift; be careful not to hit the outer bearings.

  4.  
  5. Install the snap ring onto the shaft; make sure that the snap ring is fully seated in the groove.
  6.  
  7. If installing a new boot, distribute 1 / 2 of the grease in the service package inside the tri-pod housing and the other 1 / 2 inside the boot.
  8.  
  9. Carefully, slide the spider assembly and shaft into the tri-pod housing.
  10.  
  11. Position the inner boot clamp evenly on the sealing boot.
    WARNING
    The seal must not be dimpled, stretched or out of shape. If necessary, use a trim stick to seat and equalize the seal pressure and shape it by hand.


    NOTE
    If using a Hytrel (hard plastic) boot, be sure the stick is inserted between the soft rubber insert and the tri-pod housing, not between the hard plastic sealing boot and the soft rubber insert.

  12.  
  13. Position the boot onto the tri-pod housing retaining groove and install the retaining clamp evenly on the boot.
  14.  
  15. If using a crimp type boot clamp, perform the following procedure:
    1. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
    2.  
    3. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
    4.  

  16.  
  17. If using a latching type boot clamp, perform the following procedure:
    1. Position Snap-On® Clamp Locking Tool YA3050 prongs in the clamp holes.
    2.  
    3. Squeeze the tool until the upper clamp band is latched behind the 2 tabs on the lower clamp band.
    4.  

  18.  
  19. Install the halfshaft into the vehicle.
  20.  

Outer Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable.



    The halfshaft and place it in a soft-jawed vise
     
    The Rzeppa joint boot clamps and slide the boot down the shaft
     
    The Rzeppa joint housing by sharply hitting it with a soft-faced hammer to drive it off the shaft
     
    The circlip from the shaft
     
    The boot by sliding it off the shaft
     



    Click image to see an enlarged view

    Fig. Aligning the cross splines with the shaft splines-Rzeppa joint



    Click image to see an enlarged view

    Fig. Driving the Rzeppa joint onto the shaft

  4.  

To install:

  1. Install or connect the following:

    The new small boot clamp and slide it onto the shaft
     
    The boot and slide it onto the shaft
     
    The circlip, if removed
     

  2.  
  3. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove.
  4.  
  5. Install the halfshaft hub nut onto the Rzeppa joint threaded shaft so it is flush with the end.
  6.  
  7. Install the Rzeppa joint and align the shaft splines and tap it onto the shaft with a soft-faced hammer so it locks on the circlip.
  8.  
  9. Distribute 1 / 2 of the grease in the service package inside the Rzeppa joint housing and the other 1 / 2 inside the boot.
  10.  
  11. Install a new small boot clamp and position it evenly on the sealing boot.
  12.  
  13. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
    WARNING
    The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand.

  14.  
  15. Position the boot onto the Rzeppa housing retaining groove and install the retaining clamp evenly on the boot.
  16.  
  17. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
    WARNING
    The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand.

  18.  
  19. Install the halfshaft into the vehicle.
  20.  

Removal & Installation




NOTE
If the vehicle is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or the proper equivalent tools and install them to the hubs.


WARNING
If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    Use of improper methods of joint separation can result in damage to the joint, leading to possible failure.


    NOTE
    After pressing the outer shaft, insert a pry bar between the transaxle case and the halfshaft and pry the shaft from the transaxle.


    WARNING
    Do not pull on the shaft. This could damage the inboard joint. Do not insert the pry bar too far or the oil seal in the case may be damaged.



    The negative battery cable
     
    The cotter pin, nut lock, and spring washer
     
    The halfshaft nut, loosen it while the vehicle is on the floor with the brakes applied
     
    The wheel
     
    The brake caliper assembly and support it on a wire
     
    The brake rotor
     
    The halfshaft nut and washer
     
    The tie rod end from the steering knuckle using Joint Separation Tool MB991113
     



    The speed sensor cable routing bracket, if equipped with an Anti-lock Brake System (ABS)
     
    The sway bar link from the damper fork, if necessary
     
    The damper fork assembly
     
    The steering knuckle from the lower control arm
     
    The halfshaft by pressing it from the hub
     



    Click image to see an enlarged view

    Fig. Carefully remove the outer CV-joint from the steering knuckle-be careful NOT to damage the threads or splines on the joint



    Click image to see an enlarged view

    Fig. Inserting the pry bar too far may damage the transaxle seal

  4.  

To install:

  1. Inspect the halfshaft boot for damage or deterioration. Check the ball joints and splines for wear.
  2.  
  3. Replace the circlips on the ends of the halfshaft(s).
  4.  
  5. Install or connect the following:
    NOTE
    Before securely tightening the axle nut, be sure there is no load on the wheel bearings.



    The halfshaft into the transaxle until it is fully seated
     
    The halfshaft into the hub by pulling the knuckle assembly outward
     
    The washer. Make sure the chamfered edge faces outward
     
    The halfshaft nut and tighten temporarily
     
    The control arm to the steering knuckle and torque the nuts to 43-52 ft. lbs. (59-71 Nm)
     
    The damper fork and torque the lower through-bolt/nut to 65 ft. lbs. (88 Nm) and the upper pinch bolt to 76 ft. lbs. (103 Nm)
     
    The tie rod end to the steering knuckle and torque the nut to 17-25 ft. lbs. (24-33 Nm) and install the a new cotter pin
     
    The sway bar link to the damper fork and torque the link nut to 29 ft. lbs. (39 Nm)
     
    The lock washer and axle nut and torque the nut to 145-188 ft. lbs. (200-260 Nm)
     



    The brake rotor and caliper assembly
     
    The new cotter pin
     
    The wheel. Tighten the wheel lug nuts to 100 ft. lbs. (136 Nm)
     
    The negative battery cable
     

  6.  
  7. Check and fill the transaxle with the proper amount and type of fluid.
  8.  
  9. Test drive the vehicle and check for proper operation.
  10.  

 
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