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
Inner CV Boot

CAUTION
The inner tripod joints will use a retaining clip inside the housing to keep the spider assembly in the housing. Do not pull on the interconnecting shaft to disengage tripod housing from transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing boots.

  1. Remove the halfshaft requiring boot replacement from the vehicle.
  2.  
  3. Remove large boot clamp (2) that retains inner tripod joint sealing boot to tripod joint housing (3) and discard. Then remove small clamp (1) that retains inner tripod joint sealing boot to interconnecting shaft (5) and discard. Remove the sealing boot (4) from the tripod housing and slide it down the interconnecting shaft.
    CAUTION
    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.



    Click image to see an enlarged view

    Fig. Removing CV boot.

  4.  
  5. Slide the interconnecting shaft and spider assembly (2) out of the tripod joint housing (1).

    Click image to see an enlarged view

    Fig. Slide the interconnecting shaft and spider assembly (2) out of the tripod joint housing (1).

  6.  
  7. Remove snap ring (3) that retains spider assembly (2) to interconnecting shaft (1).

    Click image to see an enlarged view

    Fig. Remove snap ring (3) that retains spider assembly (2) to interconnecting shaft (1).

  8.  
  9. Remove the spider assembly (1) from interconnecting shaft (4). If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift (3). Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft.

    Click image to see an enlarged view

    Fig. Remove the spider assembly (1) from interconnecting shaft (4).

  10.  
  11. Slide sealing boot off interconnecting shaft.
  12.  
  13. Thoroughly clean and inspect 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. Component parts of these halfshaft assemblies are not serviceable.
  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 inner tripod joint seal boot retaining clamp onto interconnecting shaft (4). Then slide the replacement inner tripod joint sealing boot (1) 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 (2) is in groove (3) on interconnecting shaft.
    NOTE
    The rollers can fall off, use caution when installing the tripod



    Click image to see an enlarged view

    Fig. Tripod joint sealing boot (1) Raised bead on inside of boot (2) Groove (3) Interconnecting shaft (4)

  2.  
  3. Install spider assembly (1) onto interconnecting shaft with chamfer (3) on spider assembly toward interconnecting shaft (2).

    Click image to see an enlarged view

    Fig. Install spider assembly (1) onto interconnecting shaft (2).

  4.  
  5. Spider assembly must be installed on 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.
  6.  
  7. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of 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 (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot.
  10.  
  11. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft.
  12.  
  13. Install inner tripod joint seal boot to interconnecting shaft clamp (3) evenly on sealing boot.

    Click image to see an enlarged view

    Fig. Install inner tripod joint seal boot to interconnecting shaft clamp (3).

  14.  
  15. Clamp sealing boot (4) onto interconnecting shaft using Clamp C-4975-A (1) and the following procedure. Place Clamp C-4975-A over bridge of clamp.
  16.  
  17. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together (2), 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.

  18.  
  19. Position sealing boot into the tripod retaining groove. Install seal boot retaining clamp evenly on sealing boot.
    CAUTION
    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.


    CAUTION
    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 (4) between the tripod (3) and the sealing boot (1) 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 trim stick is inserted between soft rubber insert and tripod housing, and not the hard plastic sealing boot and soft rubber insert.

    Click image to see an enlarged view

    Fig. Venting the inner tripod joint assembly (3).

  22.  
  23. With trim stick inserted between sealing boot (2) and tripod joint housing (4), position inner tripod joint on halfshaft until correct sealing boot edge to edge length (1) is obtained for type of sealing boot material being used. Then remove the trim stick.

    Click image to see an enlarged view

    Fig. Sealing boot edge to edge length (1)

  24.  
  25. Clamp 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 Clamp C-4975-A. Place Clamp C-4975-A over bridge of clamp.
  26.  
  27. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together, face-to-face.
  28.  
  29. If seal boot (3) uses low profile latching type boot clamp, clamp sealing boot onto tripod housing using Clamping Tool, Snap-On® YA3050 (2) (or an equivalent). Place prongs of Clamp Locking Tool in the holes of the clamp (1).

    Click image to see an enlarged view

    Fig. Clamp (1) Clamping tool, Snap-On® YA3050 (2) Sealing boot (3)

  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 requiring boot replacement back on the vehicle.
  34.  

Outer CV Boot
  1. Remove halfshaft assembly requiring boot replacement from vehicle.
  2.  
  3. Remove large boot clamp (4) retaining CV joint sealing boot to CV joint housing (3) and discard. Remove small clamp (1) that retains outer CV joint sealing boot to interconnecting shaft (5) and discard. Remove sealing boot (2) from outer CV joint housing and slide it down interconnecting shaft.

    Click image to see an enlarged view

    Fig. Removing outer CV boot.

  4.  
  5. Wipe away grease to expose outer CV joint and interconnecting shaft.
  6.  
  7. 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.
  8.  
  9. Remove large circlip (3) from the interconnecting shaft (2) before attempting to remove outer CV joint sealing boot.

    Click image to see an enlarged view

    Fig. Remove large circlip (3) from the interconnecting shaft (2).

  10.  
  11. Slide sealing boot off interconnecting shaft.
  12.  
  13. Thoroughly clean and inspect outer CV joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable.
  14.  

To install:

  1. Slide new sealing boot clamp onto interconnecting shaft. Slide the outer CV joint assembly sealing boot onto the interconnecting shaft. 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.
  2.  
  3. Install large circlip on the interconnecting shaft.
  4.  
  5. Align splines on interconnecting shaft with splines on cross of outer CV joint assembly and start outer CV joint onto interconnecting shaft.
  6.  
  7. Install outer CV joint assembly onto interconnecting shaft by using a soft-faced hammer (1) and tapping end of stub axle (2) (with hub nut (4) installed) until outer CV joint (3) is fully seated on interconnecting shaft.

    Click image to see an enlarged view

    Fig. Installing outer CV joint assembly onto interconnecting shaft.

  8.  
  9. Outer CV joint assembly must be installed on interconnecting shaft until cross (2) of outer CV joint assembly (3) is seated against circlip on interconnecting shaft (1).

    Click image to see an enlarged view

    Fig. Install outer CV joint assembly onto interconnecting shaft until cros (2) is seated against circlip.

  10.  
  11. Distribute 1 / 2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV joint assembly housing. Put the remaining amount into the sealing boot (4).
  12.  
  13. Install outer CV joint sealing boot to interconnecting shaft clamp evenly on sealing boot.
  14.  
  15. Clamp sealing boot onto interconnecting shaft using crimper, Clamp C-4975-A and the following procedure. Place Clamp C-4975-A over bridge of clamp.
  16.  
  17. 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.

  18.  
  19. Position 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.
  20.  
  21. Clamp 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.
  22.  
  23. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together, face to face.
  24.  
  25. Install the halfshaft requiring boot replacement back on the vehicle.
  26.  

Removal & Installation



  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear wheel.
  4.  
  5. Drain the fluid from the rear differential.
  6.  
  7. Remove the rear driveshaft.
  8.  
  9. Remove the sway bar connecting nuts and roll the sway bar down and out of the way, if equipped.
  10.  
  11. Remove the left and right rear halfshaft stay bracket bolts.
  12.  
  13. Remove the exhaust system up to the catalytic converter.
  14.  
  15. Support the rear differential module with a suitable jack.
  16.  
  17. Remove the rear bolt supporting the rear differential module.
  18.  
  19. Remove the two side bolts supporting the rear differential module.

    Click image to see an enlarged view

    Fig. Location of the two side bolts and left side stay bracket bolts (2) for the rear differential module (2)-Left side rear halfshaft removal

  20.  
  21. Using the jack, lower the differential module enough to gain access to the electrical connector and bracket.
  22.  
  23. Remove the routing bracket bolt and unplug the electrical connector.
  24.  
  25. Lower the rear axle assembly.
  26.  
  27. Disengage the axle shaft.
  28.  
  29. Remove the nut and washer connecting the halfshaft to left rear hub.
  30.  
  31. Remove the halfshaft from the vehicle. If it-s hard to remove, use a punch and hammer to tap it out.
  32.  

To install:

  1. Lift the rear axle assembly as the halfshaft is being installed.
  2.  
  3. Install the nut and washer connecting halfshaft to the left rear hub and tighten to 180 ft. lbs. (244 Nm).
  4.  
  5. Connect the electrical connector, route the wiring harness into the bracket. Tighten the bracket bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Lift the rear axle assembly completely into place.
  8.  
  9. Install the two differential module side bolts and tighten to 75 ft. lbs. (102 Nm).
  10.  
  11. Install the rear differential module rear bolt and tighten to 75 ft. lbs. (102 Nm).
  12.  
  13. Install the halfshaft stay bracket and tighten the bolts to 45 ft. lbs. (61 Nm).
  14.  
  15. Install the driveshaft.
  16.  
  17. Refill the rear differential module to the correct level.
  18.  
  19. If equipped, roll the sway bar into place and tighten the nuts to 45 ft. lbs. (61 Nm).
  20.  
  21. Install any exhaust components removed.
  22.  
  23. Install the wheel.
  24.  

 
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