Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

CV-Joints

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Overhaul



Not for Dodge Stratus Sedan


WARNING
The Birfield joint assembly, located on the wheel side of the halfshaft, is not to be disassembled; repair of this joint is only by replacement of the halfshaft.

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.

Birfield Joint Boot
  1. Remove halfshaft and place it in a soft jawed vise.
  2.  
  3. Disassemble or remove:

    Tri-pot joint
     
    Dynamic damper, if equipped
     
    Birfield joint boot bands
     
    Birfield joint boot

    Click image to see an enlarged view

    Fig. Positioning the birfield joint boot-s small diameter



    Click image to see an enlarged view

    Fig. View of the band crimper tool



    Click image to see an enlarged view

    Fig. Positioning the birfield joint boot-s small band



    Click image to see an enlarged view

    Fig. Measuring the small band-s crimp



    Click image to see an enlarged view

    Fig. Positioning the birfield joint boot-s large diameter



    Click image to see an enlarged view

    Fig. Positioning the birfield joint boot-s large band

     

  4.  

To install:

  1. Assemble or install:

    Birfield joint boot
     
    Birfield joint boot small band
     

  2.  
  3. Place the halfshaft in a soft jawed vise so that the birfield joint is standing vertically.
  4.  
  5. Position the boots small diameter so that only 1 groove is exposed on the shaft.
  6.  
  7. Adjust the Band Crimper Tool MB991561 or suitable band crimper so that the jaw opening is 0.114 in. (2.9mm).
  8.  
  9. Position the small band so there is clearance between the boot and the bands mating edge.
  10.  
  11. Using a Band Crimper Tool MB991561 or suitable crimper, crimp the small band until the internal measurement of the crimp is 0.094-0.110 in. (2.4-2.8mm).
    WARNING
    If the crimp dimension is not correct, remove the band install a new one.

  12.  
  13. Using 5.47 oz. (155g) specified amount of grease in the repair kit, pack the birfield boot.
  14.  
  15. Position the boot so 0.004-0.061 in. (0.1-1.55mm) of clearance exists between the boot's large diameter end and the birfield joint housing shoulder.
  16.  
  17. Adjust the Band Crimper Tool MB991561 or suitable tool so that the jaw opening is 0.126 in. (3.2mm).
  18.  
  19. Install and position the large boot band so that it rests against the boot(s) projection and a gap exists between the clamp and the boot.
  20.  
  21. Using a Band Crimper Tool MB991561 or suitable tool, crimp the small band until the internal measurement of the crimp is 0.094-0.110 in. (2.4-2.8mm).
    WARNING
    If the crimp dimension is not correct, remove the band install a new one.

  22.  
  23. If equipped, install the dynamic damper by performing the following procedure:
    1. Slide the damper onto the halfshaft with new bands.
    2.  
    3. Position the damper so the distance from the front of the birfield joint to the front edge of the damper assembly is 14.60-14.84 in. (371-377mm) for the right halfshaft or 7.52-7.76 in. (191-197mm) for the left halfshaft.
    4.  
    5. Tighten and secure the damper bands.
    6.  

  24.  
  25. Install the tri-pot joint.
  26.  

Center Bearing
  1. Remove the right halfshaft and place it in a soft-jawed vise.
  2.  
  3. Remove the tri-pot spider assembly from the tri-pot case.
  4.  
  5. Remove the tri-pot case by performing the following procedure:
    1. Position the inner shaft/tri-pot case assembly on a hydraulic press supported by Tool MB991248 or spacer plate with the tri-pot case facing upward.
    2.  
    3. Position a bar inside the tri-pot case, on the end of the inner shaft and press the case from the inner shaft assembly.
    4.  

  6.  
  7. Place the inner shaft assembly in a soft-jawed vise.
  8.  
  9. Using a wheel puller, press the center bearing bracket from the inner shaft.
  10.  
  11. Using a hydraulic press, Installer Adapter Tool MB990932 and Snap-in Bar Tool MB990938 or suitable mandrels, press the center bearing and inner dust seal from the center bearing bracket.
  12.  

To install:

  1. Using a hydraulic press, Installer Adapter Tool MB990932 and Snap-in Bar Tool MB990938 or mandrels, press the center bearing into the center bearing bracket.
  2.  
  3. Using a hydraulic press, Installer Adapter Tool MB990933 and Snap-in Bar Tool MB990938 or mandrels, press the inner duct seal into the center bearing bracket.
  4.  
  5. Using a hydraulic press, Installer Adapter Tool MB990931 and Snap-in Bar Tool MB990938 or mandrels, press the outer duct seal into the center bearing bracket.
  6.  
  7. Using a hydraulic press and Adapter Tool MB991172 or suitable mandrel, press the inner shaft into the center bearing bracket.
  8.  
  9. Install the tri-pot case onto the right halfshaft by performing the following procedure:
    1. Lubricate the inner shaft splines with Multi-Mileage Grease No. 2525035.
    2.  
    3. Press the inner shaft assembly into tri-pot case.
    4.  
    5. Secure the tri-pot case with special Tool MB991248 or spacer plate on a hydraulic press with the case facing upward.
    6.  
    7. Position a new seal plate in the center of the tri-pot case.
    8.  
    9. Place a 1.18 in. (30mm) pipe on the seal plate and press the seal into the tri-pot case.
    10.  

  10.  
  11. Assemble the tri-pot joint assembly.
  12.  
  13. Install the right halfshaft.
  14.  

Tripod Joint
2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove halfshaft and place it in a soft jawed vise.
  4.  
  5. Disassemble or remove:
    WARNING
    Do not disassemble the spider assembly.


    WARNING
    If the boot is to be reused, wrap plastic tape around the shaft splines to protect the boot from damage.



    Tri-pot boot bands
     
    Tri-pot case and remove any grease from the case
     
    Halfshaft snapring
     
    Tri-pot spider assembly
     



    Tri-pot boot
     

  6.  
  7. If necessary, remove the dynamic damper bands and slide the damper from the halfshaft.

    Click image to see an enlarged view

    Fig. Exploded view of the halfshaft assemblies-2.0L (DOHC) Engine



    Click image to see an enlarged view

    Fig. Positioning the dynamic damper on the halfshaft assemblies-2.0L (DOHC) Engine

  8.  

To install:

  1. If removed, install the dynamic damper by performing the following procedure:
    1. Slide the damper onto the halfshaft with new bands.
    2.  
    3. Position the damper so the distance from the front of the birfield joint to the front edge of the damper assembly is 14.60-14.84 in. (371-377mm) for the right halfshaft or 7.52-7.76 in. (191-197mm) for the left halfshaft.
    4.  
    5. Tighten and secure the damper bands.
      WARNING
      Wrap plastic tape around the shaft splines to protect the boot from damage.

    6.  

  2.  
  3. Install a new small boot clamp onto the halfshaft followed by the tri-pot boot.
  4.  
  5. Apply the specified repair kit grease between the spider axle and the roller.
  6.  
  7. Install the tri-pot spider assembly onto the shaft from the spline beveled section direction and secure with the snapring.
  8.  
  9. Distribute a portion of the 3.7 oz. (105 g) specified repair kit grease into the tri-pot case, insert the spider assembly and add the remaining grease.
  10.  
  11. Install the tri-pot boot by performing the following procedure:
    1. Position the boots large end on the tri-pot case.
    2.  
    3. Position the large and small boot clamps onto the boot.
    4.  
    5. Adjust the boot so that the bands are spaced at 3.03-3.27 in. (77-83mm).
    6.  
    7. Tighten the band securely.

      Click image to see an enlarged view

      Fig. Lubricating the tri-pot spider assembly



      Click image to see an enlarged view

      Fig. Lubricating the tri-pot case assembly installed



      Click image to see an enlarged view

      Fig. Measuring the tri-pot joint boot

    8.  

  12.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove halfshaft and place it in a soft jawed vise.
  4.  
  5. Disassemble or remove:
    NOTE
    Wipe the grease from the tri-pot case.


    WARNING
    Do not disassemble the spider assembly.


    WARNING
    If the boot is to be reused, wrap plastic tape around the shaft splines to protect the boot from damage.



    Tri-pot boot bands
     
    Tri-pot case for left halfshaft or tri-pot case/inner shaft assembly for right halfshaft
     



    Halfshaft snapring
     
    Tri-pot spider assembly
     



    Tri-pot boot
     

  6.  
  7. If working with the right halfshaft and it is necessary to replace the tri-pot case, press the case from the inner shaft assembly.

    Click image to see an enlarged view

    Fig. Pressing out the inner shaft from the center bearing

  8.  

To install:

  1. If installing a new tri-pot case onto the right halfshaft, perform the following procedure:
    1. Lubricate the inner shaft splines with Multi-Mileage Grease No. 2525035.
    2.  
    3. Press the inner shaft assembly into tri-pot case.
    4.  
    5. Secure the tri-pot case with special Tool MB991248 or a suitable spacer plate on a hydraulic press with the case facing upward.
    6.  
    7. Position a new seal plate in the center of the tri-pot case.
    8.  
    9. Place a 1.18 in. (30mm) pipe on the seal plate and press the seal into the tri-pot case.
      WARNING
      Wrap plastic tape around the shaft splines to protect the boot from damage.

    10.  

  2.  
  3. Install a new small boot clamp onto the halfshaft followed by the tri-pot boot.
  4.  
  5. Apply the specified repair kit grease between the spider axle and the roller.
  6.  
  7. Install the tri-pot spider assembly onto the shaft from the spline beveled section direction and secure with the snapring.
  8.  
  9. Distribute a portion of the 4.23 oz. (120 g) specified repair kit grease into the tri-pot case, insert the spider assembly and add the remaining grease.
  10.  
  11. Install the tri-pot boot by performing the following procedure:
    1. Position the boots large end on the tri-pot case.
    2.  
    3. Position the large and small boot clamps onto the boot.
    4.  
    5. Adjust the boot so that the bands are spaced at 3.03-3.27 in. (77-83mm).
    6.  
    7. Tighten the band securely.

      Click image to see an enlarged view

      Fig. Exploded view of the halfshaft assemblies

    8.  

  12.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove halfshaft and place it in a soft jawed vise.
  4.  
  5. Disassemble or remove:
    NOTE
    Wipe the grease from the tri-pot case.


    WARNING
    Do not disassemble the spider assembly.


    WARNING
    If the boot is to be reused, wrap plastic tape around the shaft splines to protect the boot from damage.



    Tri-pot boot bands
     
    Tri-pot case for left halfshaft or tri-pot case/inner shaft assembly for right halfshaft
     



    Halfshaft snapring
     
    Tri-pot spider assembly
     



    Tri-pot boot
     

  6.  
  7. If working with the right halfshaft and it is necessary to replace the tri-pot case, press the case from the inner shaft assembly.

    Click image to see an enlarged view

    Fig. Exploded view of the halfshaft assemblies-2.5L (SOHC) Engine

  8.  

To install:

  1. If installing a new tri-pot case onto the right halfshaft, perform the following procedure:
    1. Lubricate the inner shaft splines with Multi-Mileage Grease No. 2525035.
    2.  
    3. Press the inner shaft assembly into tri-pot case.
    4.  
    5. Secure the tri-pot case with special Tool MB991248 on a hydraulic press with the case facing upward.
    6.  
    7. Position a new seal plate in the center of the tri-pot case.
    8.  
    9. Place a 1.18 in. (30mm) pipe on the seal plate and press the seal into the tri-pot case.
      WARNING
      Wrap plastic tape around the shaft splines to protect the boot from damage.

    10.  

  2.  
  3. Install a new small boot clamp onto the halfshaft followed by the tri-pot boot.
  4.  
  5. Apply the specified repair kit grease between the spider axle and the roller.
  6.  
  7. Install the tri-pot spider assembly onto the shaft from the spline beveled section direction and secure with the snapring.
  8.  
  9. Distribute a portion of the 4.23 oz. (120 g) specified repair kit grease into the tri-pot case, insert the spider assembly and add the remaining grease.
  10.  
  11. Install the tri-pot boot by performing the following procedure:
    1. Position the boots large end on the tri-pot case.
    2.  
    3. Position the large and small boot clamps onto the boot.
    4.  
    5. Adjust the boot so that the bands are spaced at 3.03-3.27 in. (77-83mm).
    6.  
    7. Tighten the band securely.
    8.  

  12.  

 
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