Caliber 2007

Halfshafts

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CV-Joints



Overhaul
Inner Joint
  1. Remove the halfshaft from the vehicle.
  2.  
  3. Remove large boot clamp that retains inner tripod joint sealing boot to tripod joint housing and discard. Then remove small clamp that retains inner tripod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft.
    WARNING
    When removing the spider joint from the tripod joint housing, hold the rollers in place on the spider trunions to prevent the rollers and needle bearings from falling away.

  4.  
  5. Slide the interconnecting shaft and spider assembly out of the tripod joint housing.
  6.  
  7. Remove snap ring that retains spider assembly to interconnecting shaft.
  8.  
  9. 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. Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft.
  10.  
  11. Slide the sealing boot off the interconnecting shaft.
  12.  
  13. Thoroughly clean and inspect the spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the halfshaft assembly will require replacement.
    NOTE
    Component parts of these halfshaft assemblies are not serviceable.



    Click image to see an enlarged view

    Fig. Small clamp (1), Large boot clamp (2), tripod joint housing (3), sealing boot (4) and interconnecting shaft (5)



    Click image to see an enlarged view

    Fig. Slide the interconnecting shaft and spider assembly (2) out of the tripod joint housing



    Click image to see an enlarged view

    Fig. Remove the snap ring (3) that holds the spider assembly (2) to the shaft (1)

  14.  

To install:


NOTE
The inner tripod joint sealing boots are made from two different types of material. High-temperature applications (close to exhaust system) use silicone rubber whereas standard temperature applications use Hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot that was removed.

  1. Slide the inner tripod joint seal boot retaining clamp onto the interconnecting shaft. Then slide the replacement inner tripod joint sealing boot onto 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.
    WARNING
    The rollers can fall off, use caution when installing the tripod

  2.  
  3. Install the spider assembly onto the interconnecting shaft with chamfer on the spider assembly toward the interconnecting shaft.
  4.  
  5. The spider assembly must be installed on the interconnecting shaft far enough to fully install spider retaining snap ring. 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.

    Click image to see an enlarged view

    Fig. If necessary, the spider assembly (2) can be installed on the shaft (3) using a brass drift (4)

  6.  
  7. Install the spider assembly-to-interconnecting shaft retaining snap ring into the groove on end of the interconnecting shaft. Be sure the snap ring is fully seated into groove on interconnecting shaft.
  8.  
  9. Distribute 1 / 2 the amount of grease provided in the seal boot service package into tripod housing. Put the remaining amount into the sealing boot.
    WARNING
    Use only the grease provided in the seal boot service package.

  10.  
  11. Align tripod housing with the spider assembly and then slide tripod housing over spider assembly and interconnecting shaft.
  12.  
  13. Install the inner tripod joint seal boot-to-interconnecting shaft clamp evenly on the sealing boot.
  14.  
  15. Clamp the sealing boot onto the interconnecting shaft using Special Tool C-4975-A Clamp and the following procedure. Place Clamp C-4975-A over bridge of clamp.
  16.  
  17. Tighten the nut on Clamp C-4975-A until jaws on the tool are closed completely together, face to face.
    NOTE
    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. Tighten the nut on Clamp C-4975-A (1) until completely closed to tighten the boot seal (2)

  18.  
  19. Position the sealing boot into the tripod 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, 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 while being vented, the sealing boot can not be used.

  20.  
  21. Insert a trim stick between the tripod 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 the trim stick is inserted between soft rubber insert and tripod housing, and not the hard plastic sealing boot and soft rubber insert.
  22.  
  23. With the trim stick inserted between the sealing boot and tripod joint housing, position the inner tripod joint on halfshaft until correct sealing boot edge to edge length is obtained for type of sealing boot material being used. Then remove the trim stick.
  24.  
  25. Clamp the tripod joint sealing boot to tripod joint using required procedure for type of boot clamp application. If seal boot uses crimp type boot clamp, clamp sealing boot onto tripod housing using Special Tool C-4975-A Clamp. Place Clamp C-4975-A over bridge of clamp.
  26.  
  27. Tighten the nut on Clamp C-4975-A until jaws on tool are closed completely together, face-to-face.
  28.  
  29. If seal boot uses low profile latching type boot clamp, clamp sealing boot onto tripod housing using Clamping Tool, Snap-On® YA3050, or equivalent. Place the prongs of Clamp Locking Tool in the holes of the clamp.
  30.  
  31. Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp.
  32.  
  33. Install the halfshaft onto the vehicle.
  34.  

Outer Joint
  1. Remove the halfshaft from the vehicle.
  2.  
  3. Remove the 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.
  8.  
  9. Wipe away the grease to expose outer CV-joint and interconnecting shaft.
  10.  
  11. Remove outer CV-joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer, sharply hit the end of the CV-joint housing to dislodge housing from internal circlip on interconnecting shaft. 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. Use a soft-faced hammer (1) to sharply hit the end of the CV-joint to dislodge the housing from the internal circlip (3)

  12.  
  13. Remove large circlip from the interconnecting shaft before attempting to remove outer CV-joint sealing boot.

    Click image to see an enlarged view

    Fig. Remove the large circlip (3) from the interconnecting shaft (2) using a suitable snapring pliers (1)

  14.  
  15. Slide the sealing boot off interconnecting shaft.
  16.  
  17. Thoroughly clean and inspect outer CV-joint assembly and interconnecting joint for any signs of excessive wear.
    NOTE
    If any parts show signs of excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable.

  18.  

To install:

  1. Slide the new sealing boot clamp onto the interconnecting shaft. Slide the outer CV-joint assembly sealing boot onto the interconnecting shaft.
    WARNING
    Seal boot MUST be positioned on the interconnecting shaft so the raised bead on the inside of the seal boot is in groove on the interconnecting shaft.

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

    Click image to see an enlarged view

    Fig. Use a soft-face hammer (1) to tap the end of the stab axle (2) with the hub nut (4) installed until the CV-joint (3) is fully seated

  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.

    Click image to see an enlarged view

    Fig. Press the joint assembly (3) on the shaft until the cross (2) is seated against the circlip on the interconnecting shaft (1)

  8.  
  9. Distribute 1 / 2 the amount of grease provided in the seal boot service package into tripod housing. Put the remaining amount into the sealing boot.
  10.  
  11. Install the outer CV-joint sealing boot-to-interconnecting shaft clamp evenly on sealing boot.
  12.  
  13. Clamp the sealing boot onto the interconnecting shaft using crimper, Special Tool Clamp C-4975-A and the following procedure. Place Clamp C-4975-A over bridge of clamp.
  14.  
  15. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together, face to face. CAUTION: 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.
  16.  
  17. Position the 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.
  18.  
  19. Clamp the sealing boot onto outer CV-joint housing using Clamp C-4975-A and the following procedure. Place Clamp C-4975-A over bridge of clamp.
  20.  
  21. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together, face to face.
  22.  
  23. Install the halfshaft onto the vehicle.
  24.  

Removal & Installation



  1. Place the automatic transaxle, if equipped, in PARK.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the front wheel.
  8.  
  9. Remove the cotter pin, nut lock, spring washer and hub nut from the outer axle.

    Click image to see an enlarged view

    Fig. Exploded view of the halfshaft retaining hardware-Cotter pin (1), nut lock (5), spring washer (4) and hub nut (3) and washer (2)-Front halfshaft

  10.  
  11. If equipped with ABS, disconnect the front speed sensor.
  12.  
  13. Remove the ball joint retaining bolt and nut.
  14.  
  15. Carefully separate the ball joint stud from the steering knuckle by prying down on the lower control arm.
  16.  
  17. Remove the halfshaft from the steering knuckle by pulling outward on knuckle while pressing in on halfshaft. Support the outer end of halfshaft assembly. If you have difficulty in separating halfshaft from hub is encountered, do not strike shaft with hammer, instead use Special Tool 1026 Puller to separate.

    Click image to see an enlarged view

    Fig. If it is difficult to remove the halfshaft (2), use Special Tool 1026 (1) to pull the halfshaft out

  18.  
  19. If equipped with 2WD:
    1. Remove the halfshaft bracket from the engine lower mounting bolt.
    2.  
    3. Remove the halfshaft bracket from the upper engine mounting bolts.
    4.  

  20.  
  21. Support the 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.

  22.  
  23. Remove the inner tripod joints from the side gears of the transaxle using a punch 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, 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.
  24.  
  25. Hold the 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.
    WARNING
    When removing the 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.



    Click image to see an enlarged view

    Fig. Position a punch (2) to joint extraction groove (5) to remove the inner tripod joints (4) from the transaxle-Right side front halfshaft removal



    Click image to see an enlarged view

    Fig. Hold the inner tripod joint (1) and interconnecting shaft (6) and remove the joint by pulling it straight out of the transaxle oil seal (4)

  26.  

To install:


WARNING
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 the bolt and nut to 180 ft. lbs. (244 Nm). This will ensure that the hub bearing cannot loosen.

  1. Clean all debris from the steering knuckle opening.
    WARNING
    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 the spline and oil seal sealing surfaces on the tripod joint. Lightly lubricate the oil seal sealing surface on the tripod joint with clean transmission fluid.
  4.  
  5. Holding the halfshaft assembly by the tripod joint and interconnecting shaft, install the tripod joint into transaxle side gear as far as possible by hand.
  6.  
  7. Carefully align the tripod joint with the transaxle side gears. Then grasp the halfshaft interconnecting shaft and push tripod joint into the transaxle side gear until fully seated. Test that the snap ring is fully engaged with the side gear by attempting to remove tripod joint from transaxle by hand. If the snap ring is fully engaged with side gear, the tripod joint will not be removable by hand.
  8.  
  9. If equipped with 2WD:
    1. Install the intermediate shaft bracket to the lower engine block and tighten to 55 ft. lbs. (75 Nm).
    2.  
    3. Install the intermediate shaft bracket to the upper engine mounting bolts and tighten to 55 ft. lbs. (75 Nm).
    4.  

  10.  
  11. Apply a light coating of Mopar® multipurpose wheel bearing grease on the facing flat surface of the outer CV-joint.

    Click image to see an enlarged view

    Fig. Apply a light coating of Mopar® multipurpose wheel bearing grease on the facing flat surface (1) of the outer CV-joint

  12.  
  13. Install the 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 tightened.

  14.  
  15. Install a NEW ball joint bolt and nut and tighten to 70 ft. lbs. (95 Nm).
  16.  
  17. Install the washer and hub nut and tighten the hub nut to 180 ft. lbs. (244 Nm).
  18.  
  19. Install the spring washer, nut lock and cotter pin.
  20.  
  21. Install the front wheel.
  22.  
  23. Inspect the transaxle fluid level.
  24.  
  25. Lower the vehicle.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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