Chrysler Caravan/Voyager/Town and Country 1996-1999

Halfshafts

Print

REMOVAL & INSTALLATION



Front

See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11



Click image to see an enlarged view

Fig. Fig. 1: The axle nut should be loosened before jacking the car



Click image to see an enlarged view

Fig. Fig. 2: To loosen the nut, remove the cotter pin, nut lock, and spring washer

On vehicles with Anti-Lock Brakes (ABS), each outer CV-joint will be equipped with an ABS speed sensor tone wheel, which is utilized to determine vehicle speed for ABS brake operation.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cotter pin from the end of the stub axle. Remove the nut lock and spring washer. With the brakes applied, loosen, but do NOT remove, the axle nut and washer with the vehicle still on the ground, or damage to the wheel bearing will result.
  4.  
  5. Raise and safely support the vehicle. Remove the wheel.
  6.  
  7. Remove the front brake caliper assembly from the steering knuckle assembly and support from the strut assembly using a strong piece of wire.
  8.  
  9. Remove the front brake rotor from the hub/bearing assembly.
  10.  
  11. Remove the retaining nut and washer from the halfshaft stub axle.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: With the vehicle on the ground, loosen the axle nut with an appropriately sized socket and a breaker bar



Click image to see an enlarged view

Fig. Fig. 4: Remove the axle nut and washer, and discard the nut. (A new axle nut should be used each time the axle is removed)

  1. Separate the outer tie rod from the steering knuckle.
  2.  
  3. If equipped, remove the ABS wheel speed sensor from the steering knuckle.
  4.  
  5. Remove the wheel stop from the steering knuckle, if equipped.
  6.  
  7. Remove the nut and bolt that clamps the steering knuckle to the ball joint stud. Using a prybar, pry the control arm down to release the ball stud from the steering knuckle. Be careful not to tear the ball joint grease seal when prying down from the steering knuckle.
  8.  
  9. Separate the outer CV-joint splined shaft from the hub and bearing assembly by holding the CV-joint housing and pulling the steering knuckle away. Be careful not to damage the outer CV-joint wear sleeve or separate the inner CV-joint.
  10.  
  11. Support the halfshaft assembly at the CV-joint housing. Install a prybar between the transaxle housing and the inner tripod joint (CV-joint). Pry against the inner tripod joint until the retainer snapring on the tripod joint disengages from the transaxle side gear.
  12.  
  13. Remove the halfshaft assembly from the vehicle by holding the inner tripod joint and interconnecting shaft and pulling it straight out of the transaxle side gear. Do not allow the splines or the snapring of the shaft to drag across the sealing lip of the transaxle-to-tripod joint oil seal.
  14.  

To install:
  1. Thoroughly clean the tripod joint shaft splines and oil seal contact surface. Apply a light coating of clean transaxle lubricant to the oil seal sealing surface of the tripod joint.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Using a breaker bar and a ratchet ...



Click image to see an enlarged view

Fig. Fig. 6: ... remove the ball joint pinch bolt and nut



Click image to see an enlarged view

Fig. Fig. 7: Using a prybar, CAREFULLY separate the ball joint from the steering knuckle (Be careful not to damage the speed sensor wheel or ball joint boot)

  1. Hold the halfshaft assembly by the tripod joint and interconnecting shaft and install the halfshaft assembly into the transaxle, being careful not to damage the oil seal. Be sure the inner joint clicks into place inside the differential. Check that the snapring is fully engaged by attempting to pull the halfshaft assembly out by hand. If it cannot be removed by hand, the snapring is engaged.
  2.  
  3. Thoroughly clean the steering knuckle and hub/bearing area of all debris and moisture, where the CV-joint will be installed into the steering knuckle. Also, thoroughly clean the bearing shield of the outer CV-joint.
  4.  
  5. Pull the front strut out and insert the splined outer CV-joint into the front hub.
  6.  
  7. Insert the ball joint stud into the steering knuckle clamp. Install a new steering knuckle-to-ball joint stud clamping nut and bolt. Be sure to use an exact replacement nut and bolt during installation. Tighten the bolt to 105 ft. lbs. (145 Nm).
  8.  
  9. Install the tie rod end into the steering knuckle. Tighten the tie rod end-to-steering knuckle nut to 45 ft. lbs. (61 Nm).
  10.  
  11. Install the disc brake rotor.
  12.  
  13. Install the brake caliper assembly onto the steering knuckle.
  14.  
  15. Install the axle washer and nut. Tighten the nut to about 45 ft. lbs. (61 Nm) temporarily.
  16.  
  17. If removed, install the ABS wheel speed sensor.
  18.  



Click image to see an enlarged view

Fig. Fig. 8: Once the ball joint is separated from the knuckle, pull the knuckle away from the axle and rotate it sideways



Click image to see an enlarged view

Fig. Fig. 9: It may be necessary to LIGHTLY pry outward on the inner CV joint to disengage the lock ring on the inner CV joint shaft



Click image to see an enlarged view

Fig. Fig. 10: Carefully remove the axle; do NOT let the inner splines drag on the transaxle seal during removal



Click image to see an enlarged view

Fig. Fig. 11: Make sure to tighten the outer axle nut to the proper torque specification to prevent damage to the wheel bearing

  1. Install the wheel and lug nuts. Tighten the lug nuts in a star pattern, to 95 ft. lbs. (129 Nm).
  2.  
  3. Lower the vehicle. Do NOT roll the vehicle until the axle nut has been properly tightened or damage to the front wheel bearings will result.
  4.  
  5. With the vehicle's brakes applied, tighten the axle nut to 180 ft. lbs. (244 Nm). Install the spring washer, nut lock and a new cotter pin. Wrap the cotter pin prongs tightly around the axle nut lock.
  6.  
  7. Reconnect the negative battery cable. Road test the vehicle.
  8.  

Rear

See Figures 12 and 13



Click image to see an enlarged view

Fig. Fig. 12: Disconnecting the rear halfshaft at the differential



Click image to see an enlarged view

Fig. Fig. 13: Once the outer axle nut is removed, pull the axle from the vehicle

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the rear wheel.
  6.  
  7. Remove the cotter pin from the end of the halfshaft. Remove the nut lock, spring washer, axle nut and washer.
  8.  
  9. Remove the inner shaft retaining bolts. The halfshaft is spring loaded. Compress the inner halfshaft joint slightly and pull downward to clear the differential.
  10.  
  11. Remove the halfshaft.
  12.  

To install:
  1. Install the halfshaft.
  2.  
  3. Install and tighten the inner shaft retaining bolts to 45 ft. lbs. (61 Nm).
  4.  
  5. Install the washer and nut on the axle shaft. Tighten the nut to 180 ft. lbs. (244 Nm). Install the spring washer, nut lock and a new cotter pin.
  6.  
  7. Install the wheel and lug nuts. Tighten the lug nuts to 95 ft. lbs. (129 Nm).
  8.  
  9. Lower the vehicle and reconnect the negative battery cable.
  10.  

OVERHAUL



On some models, the only service that can be performed on the halfshaft assemblies is to replace the driveshaft seal boot on the inner tripod joint.

If any failure to the internal halfshaft components is found, the halfshaft must be replaced as an assembly.

The lubricant type and amount necessary for the inner joints is different than that for the outer joints. Use only the recommended lubricants in the specified amounts when servicing the halfshafts.

Inner Tripod Joint Seal Boot

See Figures 14, 15, 16, 17, 18, 19, 20 and 21

The inner tripod joints do not use any internal retainers in the tripod housing to hold the spider assembly in the housing. Therefore, do not pull on the interconnecting shaft to detach the tripod housing from the transaxle stub shaft. Removing them in this way will damage the inboard joint sealing boots.

  1. Remove the halfshaft requiring boot replacement from the vehicle, as outlined earlier in this section.
  2.  
  3. Remove the large boot clamp that holds the inner tripod joint sealing boot to the tripod joint housing. Discard the clamp. Then, remove the small clamp that holds the inner tripod joint sealing boot to the interconnecting shaft and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft.
  4.  


WARNING
When removing the tripod joint housing from the spider joint, hold the rollers in place on the spider trunions to keep the roller and needle bearings from falling off.



Click image to see an enlarged view

Fig. Fig. 14: After discarding the boot clamps, remove the tripod joint housing from the interconnecting shaft and spider assembly



Click image to see an enlarged view

Fig. Fig. 15: Location of the spider assembly's retaining snapring



Click image to see an enlarged view

Fig. Fig. 16: If you encounter difficulty removing the spider assembly from the interconnecting shaft, use a brass drift to tap the spider

  1. Slide the interconnecting shaft and spider assembly out of the tripod joint housing.
  2.  
  3. Remove the snapring that holds the spider assembly to the interconnecting shaft. Remove the spider assembly from the interconnecting shaft. If the spider won't come off by hand, you can remove it by tapping the spider with a brass drift. Do NOT hit the outer tripod bearings trying to remove the spider assembly from the interconnecting shaft.
  4.  
  5. Slide the sealing boot off the interconnecting shaft.
  6.  
  7. Thoroughly clean and inspect the spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show extreme wear, the halfshaft must be replaced.
  8.  

To install:

The inner tripod joint sealing boots are made from two different types of material. High temperature applications 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 sealing boot retaining clamp onto the interconnecting shaft. Then, slide the replacement inner tripod joint sealing boot onto the interconnecting shaft. The inner tripod joint sealing boot MUST be positioned on the interconnecting shaft, so the raised bead on the inside of the seal boot is in the groove on the interconnecting shaft.
  2.  
  3. Install the spider assembly onto the interconnecting shaft with the chamfer on the spider assembly toward the interconnecting shaft. The spider must be positioned on the interconnecting shaft far enough to fully install the retaining snapring. If the spider assembly will not fully install by hand, you can tap the spider body with a brass drift. Do NOT hit the outer tripod bearings trying to install the spider on the interconnecting shaft.
  4.  
  5. Install the spider assembly-to-interconnecting shaft retaining snapring into the groove on the end of the interconnecting shaft. Be sure the snapring is fully seated in the groove on the interconnecting shaft.
  6.  
  7. Distribute 1 / 2 the amount of the grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into the tripod housing. Put the remaining amount into the sealing boot.
  8.  
  9. Align the tripod housing with the spider assembly, then slide the tripod housing over the spider assembly and interconnecting shaft.
  10.  
  11. Install the inner tripod joint seal boot-to-interconnecting shaft clamp evenly on the sealing boot.
  12.  
  13. Clamp the sealing boot onto the interconnecting shaft using a suitable crimper. Place the crimping tool over the bridge of the clamp. Tighten the nut on the tool until the jaws of the tool are closed completely together, face-to-face.
  14.  

The seal must not be dimpled, stretched or out-of-shape in any way. If the seal is NOT correctly shaped, equalize the pressure in the seal and shape it by hand.

Click image to see an enlarged view

Fig. Fig. 17: Installation of the sealing boot on the interconnecting shaft



Click image to see an enlarged view

Fig. Fig. 18: Tighten the nut on the crimping tool until the jaws are completely closed, face-to-face



Click image to see an enlarged view

Fig. Fig. 19: Carefully insert a small prytool or trim stick to vent the tripod joint

  1. Position the sealing boot into the tripod housing retaining groove. Install the seal boot retaining clamp evenly on the sealing boot.
  2.  


WARNING
The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly before clamping the sealing boot to the inner tripod joint housing. If this procedure is not performed before clamping the sealing boot to the tripod joint housing, boot durability can be adversely affected. When venting the inner tripod joint, be careful so the inner tripod sealing boot does not get punctured or damaged in any other way. If the sealing boot is punctured or damaged while being vented, it cannot be used.

  1. Insert a small prytool or equivalent tool between the tripod joint and sealing boot to vent the inner tripod joint assembly. When inserting the prytool between the tripod housing and the sealing boot, make sure the tool is held flat and firmly against the tripod housing. If this is not done, damage to the sealing boot can occur. If the inner tripod joint has a Hytrel® (hard plastic) boot, make sure the tool is placed between the soft rubber insert and the tripod housing, and not the hard plastic sealing boot and soft rubber insert.
  2.  
  3. With the tool inserted between the sealing boot and the tripod joint housing, position the inner tripod joint on the driveshaft until the correct sealing boot edge-to-edge length is attained for the type of sealing boot material being used. Then remove the tool.
  4.  
  5. Clamp the tripod sealing boot to the tripod joint using the proper procedure for the type of boot clamp. If the boot uses a crimp-type boot clamp, clamp the sealing boot onto the tripod housing using crimping tool C-4975-A or equivalent. Place the tool over the bridge of the clamp, then tighten the nut on the tool until the jaws are closed completely together, face-to-face.
  6.  



Click image to see an enlarged view

Fig. Fig. 20: When installing a latching-type boot clamp, position a suitable clamp locking tool on the clamp as shown ...



Click image to see an enlarged view

Fig. Fig. 21: ... then squeeze the tool together in order to properly install the latching-type clamp

  1. If the boot uses low profile, latching type boot clamps, clamp the sealing boot onto the tripod housing using clamp locking tool YA3050 or equivalent, as shown in the accompanying figure. Place the prongs of the clamp locking tool in the holes of the clamp. Squeeze the tool together until the top band of the clamp is latched behind the 2 tabs on the lower band of the clamp.
  2.  
  3. Install the halfshaft in the vehicle, as outlined earlier in this section.
  4.  

Outer CV-Joint Seal Boot

See Figures 22, 23, 24, 25 and 26

This procedure only applies to vehicles equipped with removable outer CV joints. Some 1997 and later models use a different type of axle which does not allow servicing of the outer CV joint. If the outer boot needs replacement, the inner tripod assembly will need to be removed.



Click image to see an enlarged view

Fig. Fig. 22: On models with removable outer CV joints, a circlip holds the joint to the shaft



Click image to see an enlarged view

Fig. Fig. 23: Use a soft-faced hammer to lightly tap the outer CV joint from the shaft

  1. Remove the halfshaft from the vehicle, as outlined earlier in this section.
  2.  
  3. Remove the large boot clamp that holds the inner tripod joint sealing boot to the tripod joint housing. Discard the clamp. Then, remove the small clamp that holds the inner tripod joint sealing boot to the interconnecting shaft and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft.
  4.  
  5. Wipe away the grease to expose the outer CV-joint.
  6.  
  7. Remove the outer CV-joint from the interconnecting shaft by performing the following:
    1. Place the interconnecting shaft in a soft jawed vise.
    2.  
    3. Using a soft-faced hammer, sharply hit the end of the CV-joint housing to dislodge the housing from the internal circlip on the interconnecting shaft.
    4.  
    5. Slide the outer CV-joint off the end of the interconnecting shaft; the joint may have to be tapped off using a soft-faced hammer.

      Click image to see an enlarged view

      Fig. Fig. 24: Remove the circlip from the shaft using a pair of snapring pliers before removing the boot

    6.  

  8.  
  9. Use a pair of snapring pliers to remove the large circlip from the interconnecting shaft before trying to remove the outer CV-joint sealing boot.
  10.  
  11. Slide the faulty boot off the interconnecting shaft.
  12.  
  13. Throughly clean and inspect the outer CV-joint and interconnecting joint for signs of excessive wear. If any parts show extreme wear, the halfshaft must be replaced.
  14.  

To install:
  1. Slide the new boot-to-interconnecting shaft retaining clamp onto the interconnecting shaft. Slide the outer CV-joint assembly boot onto the interconnecting shaft. The boot must be positioned on the interconnecting shaft so the raised bead of the inside of the seal boot is in the 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 and start the outer CV-joint onto the interconnecting shaft.
  4.  



Click image to see an enlarged view

Fig. Fig. 25: If necessary, use a soft faced hammer to install the outer C/V joint to the interconnecting shaft



Click image to see an enlarged view

Fig. Fig. 26: The outer CV-joint must be installed until the cross of the joint is seated against the shaft circlip

  1. Install the outer CV-joint onto the interconnecting shaft by using a soft-faced hammer and tapping the end of the stub axle (with the nut installed) until the outer CV-joint is fully seated on the shaft.
  2.  
  3. The outer CV-joint must be installed on the interconnecting shaft until the cross of the CV-joint is seated against the circlip on the shaft.
  4.  
  5. Place 1 / 2 of the grease provided with the boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into the outer CV-joint housing. Place the remaining grease into the boot.
  6.  
  7. Install the outer CV-joint boot-to-interconnecting shaft clamp evenly on the sealing boot.
  8.  
  9. Clamp the boot onto the interconnecting shaft using C-4975-A or an equivalent crimping tool, as follows:
    1. Place the crimping tool over the bridge of the clamp.
    2.  
    3. Tighten the nut on the crimping tool until the jaws on the tool are closed completely together, face-to-face.
    4.  

  10.  
  11. Position the outer CV-joint boot into its retaining groove on the outer CV-joint housing. Install the boot-to-housing clamp evenly on the housing. Install the sealing boot-to-outer CV-joint retaining clamp evenly on the sealing boot.
  12.  
  13. Clamp the boot onto the outer CV-joint housing using a suitable crimping tool. Place the crimping tool over the bridge of the clamp, then tighten the nut on the crimping tool until the jaws on the tool are closed completely together, face-to-face.
  14.  
  15. Install the halfshaft in the vehicle, as outlined earlier in this section.
  16.  

 
label.common.footer.alt.autozoneLogo