Caliber 2007

Halfshafts

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CV-Joints



Overhaul

If any parts show signs of excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable.

Removal & Installation




CAUTION
Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the CV joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage CV joints. During removal and installation procedures, always support both ends of the halfshaft to prevent damage.


CAUTION
The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N·m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.

  1. Disconnect battery negative cable.
  2.  
  3. Place transaxle in gated park.
  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Remove wheel and tire assembly.
  8.  
  9. Remove the cotter pin, nut lock, spring washer, and hub nut from the end of the outer C/V joint stub axle.
  10.  
  11. Remove hub nut.
  12.  
  13. If equipped with ABS, disconnect the front wheel speed sensor and secure harness out of the way.
  14.  
  15. Remove nut and bolt retaining the ball joint stud into steering knuckle.
    NOTE
    Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged.

  16.  
  17. Separate ball joint stud from steering knuckle by prying down on lower control arm.
    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.

  18.  
  19. Remove halfshaft from steering knuckle by pulling outward on knuckle while pressing in on halfshaft. Support outer end of halfshaft assembly. If difficulty in separating halfshaft from hub is encountered, do not strike shaft with hammer, instead use Puller 1026 to separate.
  20.  
  21. Two wheel drive vehicles, remove halfshaft bracket (2) from engine lower mounting bolt (3).

    Click image to see an enlarged view

    Fig. Remove halfshaft bracket (2) from engine lower mounting bolt (3).

  22.  
  23. Two wheel drive vehicles, remove halfshaft bracket from engine upper mounting bolts (2).

    Click image to see an enlarged view

    Fig. Remove halfshaft bracket from engine upper mounting bolts (2).

  24.  
  25. Support outer end of the halfshaft assembly.
    NOTE
    Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. Do not pull on interconnecting shaft to remove, as the inner joint will become separated.

  26.  
  27. Remove the inner tripod joints (4) from the side gears of the transaxle using a punch (2) to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch to the inner tripod joint extraction groove (5) (if equipped). Strike the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch to the inner tripod joint extraction groove. Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear.

    Click image to see an enlarged view

    Fig. Removing inner tripod joints (4) from side gears of transaxle.

  28.  
  29. Hold inner tripod joint (1) and interconnecting shaft (6) of halfshaft assembly. Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and transaxle oil seal (4).
    WARNING
    When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. When tripod joint is removed from transaxle, some fluid will leak out.


    CAUTION
    The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N·m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.



    Click image to see an enlarged view

    Fig. Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and transaxle oil seal (4).

  30.  

To install:

  1. Clean all debris and moisture out of steering knuckle.
    CAUTION
    Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the CV joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage CV joints. During removal and installation procedures, always support both ends of the halfshaft to prevent damage.

  2.  
  3. 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.
    NOTE
    Always use Seal Protector 9099 when installing half shaft into the transaxle.

  4.  
  5. Holding halfshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand.
  6.  
  7. Carefully align tripod joint with transaxle side gears. Then grasp halfshaft interconnecting shaft and push tripod joint into transaxle side gear until fully seated. 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.
  8.  
  9. Two wheel drive vehicles install halfshaft bracket-to-block and tighten bolt to 75 N·m (55 ft. lbs.).

    Click image to see an enlarged view

    Fig. Install halfshaft bracket (2) with lower mounting bolt (3).

  10.  
  11. Two wheel drive vehicles install halfshaft bracket- to-block upper mounting bolts and tighten to 75 N·m (55 ft. lbs.).

    Click image to see an enlarged view

    Fig. Install halfshaft bracket with upper mounting bolts (2).

  12.  
  13. Ensure that front of outer CV joint which fits into steering knuckle, is free of debris and moisture before assembling into steering knuckle.
  14.  
  15. Apply a light coating of MOPAR® multi-purpose wheel bearing grease around the circumference of the flat surface. Do not apply too much grease, which could spill onto the non-mating and adversely affect the function of the halfshaft.
  16.  
  17. Wipe the rear of the hub and bearing in the knuckle clean where they contact the C/V joint.
  18.  
  19. Install halfshaft back into front hub.
  20.  
  21. Install steering knuckle onto the ball joint stud.
    NOTE
    At this point, the outer joint will not seat completely into the front hub. The outer joint will be pulled into hub and seated when the hub nut is installed and tighten to specification.

  22.  
  23. Install a NEW steering knuckle to ball joint stud bolt and nut. Tighten the nut and bolt to 95 N·m (70 ft. lbs.).
  24.  
  25. Clean all foreign matter from threads of halfshaft outer stub axle.
  26.  
  27. Install washer and hub nut onto the threads of the stub axle and tighten nut to 244 N·m (180 ft. lbs.).
  28.  
  29. Install spring washer, nut lock, and cotter pin.
  30.  
  31. Install hub nut and tighten to 244 N·m (180 ft. lbs.).
  32.  
  33. Install front wheel and tire assembly. Install front wheel lug nuts and tighten to 128 N·m (95 ft. lbs.).
  34.  
  35. Check for correct fluid level in transaxle assembly.
  36.  
  37. Lower vehicle.
  38.  
  39. Connect battery negative cable.
  40.  

 
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