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

Removal & Installation

Print

  1. Raise vehicle on hoist.
  2.  
  3. Remove the front tire and wheel assembly.
  4.  
  5. Remove the caliper adapter-to-knuckle bolts.
  6.  
  7. Remove the caliper/adapter assembly and support with mechanic-s wire or equivalent. Do not support assembly by the flexible brake hose.
  8.  
  9. Remove the brake rotor.
  10.  
  11. Remove the tie rod-to-steering knuckle nut. Remove nut from tie rod end by holding tie rod end stud with an 11 / 32 socket and loosen and remove nut.
  12.  
  13. Separate tie rod end from steering knuckle arm, using Tool MB-991113, or equivalent.
  14.  
  15. Remove the halfshaft to hub and bearing retaining nut.
  16.  
  17. Remove the cotter pin and castle nut from stud of lower ball joint at the steering knuckle.
    WARNING
    No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described below.



    Click image to see an enlarged view

    Fig. Separating the ball joint stud from the steering knuckle

  18.  
  19. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike steering knuckle boss until steering knuckle separates from stud of lower ball joint. When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal.
    NOTE
    Care must be taken not to separate the inner CV-joint during this operation. Do not allow halfshaft to hang by inner CV-joint . Halfshaft must be supported.



    Click image to see an enlarged view

    Fig. Separating the halfshaft from the knuckle

  20.  
  21. Separate the halfshaft from steering knuckle. If difficulty is encountered separating halfshaft from knuckle, DO NOT strike halfshaft with a hammer to break free. Install the Puller 1026 as shown in to press shaft out of hub/bearing assembly.
    NOTE
    When inserting pry bar between inner tripod joint and transaxle case, care must be used to ensure no damage occurs to oil seal in transaxle case.



    Click image to see an enlarged view

    Fig. Disengaging the inner tripod joint from the transaxle

  22.  
  23. Support the outer end of the halfshaft assembly. Insert a pry bar between inner tripod joint and transaxle case. Pry against inner tripod joint, until tripod joint retaining snap ring is disengaged from transaxle side gear.

    Click image to see an enlarged view

    Fig. Separating the halfshaft from the hub/bearing



    Click image to see an enlarged view

    Fig. Tripod joint removal from the transaxle

  24.  
  25. Hold inner tripod joint and interconnecting shaft of halfshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal.
    NOTE
    When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal.

  26.  

To install:

  1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant.
  2.  
  3. Holding halfshaft assembly by tripod joint and interconnecting shaft, install the tripod joint into transaxle side gear as far as possible by hand.
  4.  
  5. Grasp inner tripod joint and interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand.
  6.  
  7. Clean all debris and moisture out of steering knuckle, in the area were outer CV-joint will be installed into steering knuckle.
  8.  
  9. Ensure that front of outer CV-joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer CV-joint into hub and bearing assembly.
  10.  
  11. Slide halfshaft back into front hub. Then install the steering knuckle onto the lower control arm ball joint stud.
  12.  
  13. Install the steering knuckle to ball joint stud castle nut. Tighten the castle nut to 70 ft. lbs. (95 Nm).
  14.  
  15. Install the tie rod end into the steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle nut. Using a crowfoot and 11 / 32 socket, tighten the nut to: 41 ft. lbs. (55 Nm).
  16.  
  17. Install the brake rotor to hub.
  18.  
  19. Install the caliper/adapter bracket assembly on steering knuckle. Install and torque caliper adapter-to-knuckle bolts to 65 ft. lbs. (88 Nm).
  20.  
  21. Clean all foreign matter from the threads of the outer CV-joint stub axle. Install the hub nut onto threads of halfshaft. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 110 ft. lbs. (150 Nm).
  22.  
  23. Install the front wheel and tire assembly. Install the front wheel lug nuts and tighten in the correct sequence. Tighten lug nuts to 100 ft. lbs. (135 Nm).
  24.  


NOTE
If the vehicle is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or proper equivalent tools and install the 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. Doing so damages the inboard joint. Do not insert the pry bar too far or the oil seal in the case may be damaged.



    Negative battery cable
     
    Cotter pin, nut lock and spring washer
     
    Halfshaft nut, loosen it while the vehicle is on the floor with the brakes applied
     
    Wheel
     
    Brake caliper assembly and support it on a wire
     
    Brake rotor
     
    Halfshaft nut and washer
     
    Tie rod end from the steering knuckle using Joint Separation Tool MB991113
     



    Speed sensor cable routing bracket (if equipped) with an Anti-lock Brake System (ABS)
     
    Sway bar link from the damper fork, if necessary
     
    Damper fork assembly
     
    Steering knuckle from the lower control arm
     
    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.



    Halfshaft into the transaxle until it is fully seated
     
    Halfshaft into the hub by pulling the knuckle assembly outward
     
    Washer. Make sure the chamfered edge faces outward
     
    Halfshaft nut and tighten temporarily
     
    Control arm to the steering knuckle and torque the nuts to 43-52 ft. lbs. (59-71 Nm)
     
    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)
     
    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
     
    Sway bar link to the damper fork and torque the link nut to 29 ft. lbs. (39 Nm)
     
    Lock washer and axle nut and torque the nut to 145-188 ft. lbs. (200-260 Nm)
     



    Brake rotor and caliper assembly
     
    New cotter pin
     
    Wheel
     
    Negative battery cable
     

  6.  
  7. Refill the transaxle.
  8.  
  9. Test drive the vehicle and check for proper operation.
  10.  

2.0L & 2.5L Engines




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



    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Cotter pin, halfshaft nut and washer
     
    Front wheel
     
    Tie rod end from the steering knuckle using Joint Separation Tool MB991113
     



    Sway bar link from the damper fork
     
    Damper fork lower through-bolts, upper pinch bolt and damper fork assembly
     
    Lateral arm and the compression arm from the steering knuckle using a joint separation tool
     
    Halfshaft from the hub/knuckle by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub
     
    Halfshaft from the transaxle by inserting a prybar between the transaxle case and the halfshaft
     

  4.  
  5. If equipped with a center bearing on the right halfshaft, remove the center bearing bracket-to-chassis bolts; then, tap lightly on the center bearing bracket to separate the inner shaft from the transaxle.
    WARNING
    Do not pull on the shaft. Doing so damages the inboard joint. Do not insert the prybar too far or the oil seal in the case may be damaged.

  6.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the left and right halfshaft assemblies- mounting-1999-00 vehicles shown

  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. Insert the halfshaft into the transaxle. Be sure it is fully seated.
  6.  
  7. If equipped with a center bearing on the right halfshaft, install the center bearing bracket-to-chassis bolts and torque to 30 ft. lbs. (40 Nm).
  8.  
  9. Pull the knuckle assembly outward and install the other end of the halfshaft into the hub.
  10.  
  11. Install the washer so the chamfered edge faces outward. Install the halfshaft nut and tighten temporarily.
  12.  
  13. Connect the lateral arm and the compression arm to the steering knuckle. Torque the self-locking nuts to 43-52 ft. lbs. (59-71 Nm).
  14.  
  15. Install or connect the following:
    NOTE
    Before securely tightening the axle nut, make sure there is no load on the wheel bearings.



    Damper fork then torque the lower through-bolt to 65 ft. lbs. (88 Nm) and the upper pinch bolt to 76 ft. lbs. (103 Nm)
     
    Tie rod end to the steering knuckle and torque the nut to 17-25 ft. lbs. (24-33 Nm) and install a new cotter pin
     
    Sway bar link to the damper fork and torque the nut to 29 ft. lbs. (39 Nm)
     
    Lockwasher and axle nut; then, torque the axle nut with the Special Tool MB990767 to hold the hub from turning to 145-188 ft. lbs. (200-260 Nm)
     



    New cotter pin
     
    Front wheel
     
    Negative battery cable
     

  16.  
  17. Fill the transaxle to the proper level.
  18.  
  19. Test drive the vehicle and check for proper operation.
  20.  

2.4L & 3.0L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Front wheel
     
    Vehicle Speed Sensor (VSS) cable, if equipped
     
    Brake hose clip and cotter pin
     
    Driveshaft nut
     
    Lower arm ball joint connection
     
    Tie rod end
     
    Stabilizer link
     
    Driveshaft and circlip

    Click image to see an enlarged view

    Fig. Exploded view of the left and right halfshaft assemblies

     

  4.  

To install:

  1. Install or connect the following:

    Driveshaft
     
    Stabilizer link and torque the nut to 33 ft. lbs. (44 Nm)
     
    Tie rod end and torque the nut to 21 ft. lbs. (28 Nm)
     
    New cotter pin to the tie rod end
     
    Lower arm ball joint
     
    Driveshaft nut and torque it to 167 ft. lbs. (226 Nm)
     
    New cotter pin to the driveshaft nut
     
    Brake hose clip
     
    VSS cable, if equipped
     
    Front wheel
     
    Negative battery cable
     

  2.  

Inner Tri-Pod Joint



  1. Remove the or disassemble the following:

    Negative battery cable
     
    Halfshaft
     
    Large and small boot retaining clamps
     

  2.  
  3. 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.

  4.  
  5. Carefully slide the shaft/spider assembly from the tri-pod housing.
  6.  
  7. 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.

  8.  
  9. Slide the boot off the shaft.
  10.  
  11. 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



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. View of the halfshaft boot and shaft



    Click image to see an enlarged view

    Fig. Securing the halfshaft boot clamp



    Click image to see an enlarged view

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



    Click image to see an enlarged view

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

  12.  

To assemble:


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.  

Rzeppa (Outer) Joint



  1. Remove the or disassemble the following:
    WARNING
    If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable.



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

  2.  

To assemble:

  1. Install the or assemble the following:

    New small boot clamp and slide it onto the shaft
     
    Boot and slide it onto the shaft
     
    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 or assemble the following:

    Halfshaft hub nut onto the Rzeppa joint threaded shaft so it is flush with the end
     
    Rzeppa joint and align the shaft splines and tap it onto the shaft with a soft-faced hammer so it locks on the circlip
     

  6.  
  7. Distribute 1 / 2 of the grease in the service package inside the Rzeppa joint housing and the other 1 / 2 inside the boot.
  8.  
  9. Install or connect the following:

    New small boot clamp and position it evenly on the sealing boot
     

  10.  
  11. 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.

  12.  
  13. Position the boot onto the Rzeppa housing retaining groove and install the retaining clamp evenly on the boot.
  14.  
  15. 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.

  16.  
  17. Install the halfshaft into the vehicle.
  18.  

 
label.common.footer.alt.autozoneLogo