Chrysler Caravan/Voyager/Town n Country 1984-1995

Halfshafts

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The halfshafts used on your vehicle are of three piece construction and are unequal in length and material composition. A short solid interconnecting shaft is used on the left side and a longer tubular interconnecting shaft is installed on the right side.

The halfshaft assemblies are three piece units. Each shaft has a Tripod joint on the transaxle side, an interconnecting shaft and a Rzeppa joint on the wheel side. The Rzeppa joint mounts a splined stub shaft that connects with the wheel hub. The inner Tripod joint mounts a spring that maintains constant spline engagement with the transaxle. The design enables the halfshaft to be removed without dismantling the transaxle.

Models equipped with a turbo charged engine incorporate an equal length halfshaft system. This system includes an extra intermediate shaft installed on the right side. This helps to prevent torque steer induced by the power of the engine. The halfshaft removal procedure for all vehicles is the same.

REMOVAL & INSTALLATION



See Figures 1 through 16



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Fig. Fig. 1: Halfshaft type and identification



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Fig. Fig. 2: Separating the ball joint from the knuckle



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Fig. Fig. 3: Removing the driveshaft assembly



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Fig. Fig. 4: Speedometer pinion removal and installation



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Fig. Fig. 5: Installing the inner shaft into the transaxle



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Fig. Fig. 6: Seal and wear sleeve lubrication points



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Fig. Fig. 7: Installing the outer shaft into the hub



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Fig. Fig. 8: Removing the hub nut-1987 Voyager shown



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Fig. Fig. 9: Removing the ball joint to steering knuckle clamp bolt



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Fig. Fig. 10: Remove the retaining bolt and remove the speedometer pinion from the transaxle assembly



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Fig. Fig. 11: Separate the ball joint from the knuckle by prying downward against the knuckle and arm



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Fig. Fig. 12: Separate the outer CV-joint splines from the knuckle hub by holding the CV-housing and pushing the knuckle out



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Fig. Fig. 13: Support the assembly and pull outward on the inner CV-housing to free the assembly from the transaxle



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Fig. Fig. 14: Separating the assembly from the transaxle



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Fig. Fig. 15: Removing the assembly from the transaxle



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Fig. Fig. 16: Removing the seal from the housing using a suitable prying tool

  1. Remove the cotter pin, lockwasher and spring washer from the front axle ends.
  2.  
  3. Have a helper apply the service brakes and loosen the front axle hub retaining nut.
  4.  
  5. Raise and support the front of the vehicle on jackstands.
  6.  
  7. Remove the hub nut, washer and wheel assembly. Drain transaxle fluid.
  8.  

The speedometer drive pinion must be removed from the transaxle housing before the right side drive axle can be removed. Remove the retaining bolts and lift the pinion with cable connected from the housing.

  1. Remove the clamp bolt that secures the ball joint stud with the steering knuckle.
  2.  
  3. Separate the ball joint from the knuckle by prying downward against the knuckle connecting point and the control arm. Take care not to damage the rubber boot.
  4.  
  5. Separate the outer CV-joint (Constant Velocity) splines from the steering knuckle hub by holding the CV housing and pushing the knuckle out and away. If resistance is encountered, use a brass drift and hammer to gently tap the outer hub end of the axle. Do not pry on the outer wear sleeve of the CV-joint.
  6.  
  7. After the outboard end of the drive axle has been removed from the steering knuckle, support the assembly and pull outward on the inner CV-joint housing to remove the assembly from the transaxle.
  8.  


WARNING
Do not pull on the shaft or the assembly will disconnect. Pull only on the inner CV-joint housing.

  1. Remove the halfshaft from under the vehicle and service as necessary.
  2.  

To install:
  1. When installing the halfshaft, hold the inner joint assembly by its housing, align and guide the shaft into the transaxle or intermediate shaft assembly.
  2.  
  3. Lubricate the outer wear sleeve and seal with multi-purpose grease. Push the steering knuckle outward and install the splined outer shaft into the drive hub.
  4.  
  5. Install the steering knuckle assembly. Tighten the ball joint clamp bolt to 70 ft. lbs. (95 Nm). Tighten the hub nut (splined shaft nut) to 180 ft. lbs. (250 Nm). Refill the transaxle with the proper lubrication fluid.
  6.  

If after installing the axle assembly, the inboard boot appears collapsed, vent the boot by inserting a thin round rod between the boot and the shaft. Massage the boot until is expands. Install a new clamp to prevent dirt from entering the boot.

CV-JOINT OVERHAUL



Inner Joint

See Figures 17, 18, 19, 20, 21, 22, 23, 24, 25 and 26



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Fig. Fig. 17: After removing the clamps, pull the boot to expose the tripod retention system-1987 Voyager with Citroen type CV-joint



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Fig. Fig. 18: Secure the rollers, then tap the retainer ring in 3 locations to separate the tripod from the housing



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Fig. Fig. 19: Removing the spring and cup



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Fig. Fig. 20: Separating the cup from the spring



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Fig. Fig. 21: Remove the snapring from the end of the shaft



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Fig. Fig. 22: After removing the snapring from the end of the shaft remove the tripod



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Fig. Fig. 23: Place a small amount of grease in the spring cup



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Fig. Fig. 24: Exploded view of the halfshaft assembly



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Fig. Fig. 25: Separating the tripod from the housing on a GKN type CV-joint



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Fig. Fig. 26: Spring and cup installation

  1. With the halfshaft assembly removed from the vehicle, remove the clamps and boot.
  2.  
  3. Depending on the unit (GKN or Citroen) separate the tripod assembly from the housing as follows:
  4.  

CITROEN TYPE
  1. Since the trunion ball rollers are not retained on bearing studs, a retaining ring is used to prevent accidental tripod/housing separation, which would allow roller and needle bearings to fall away.
  2.  

In the case of the spring loaded inner CV-joints, if it weren't for the retaining ring, the spring would automatically force the tripod out of the housing whenever the shaft was not installed in the vehicle.

  1. Separate the tripod from the housing by slightly deforming the retaining ring in 3 places, with a suitable tool.
  2.  


WARNING
Secure the rollers to the studs during separation. With the tripod out of the housing secure the assembly with tape.

GKN TYPE
  1. Spring loaded GKN inboard CV-joints have tabs on the can cover that prevent the spring from forcing the tripod out of the housing. These tabs must be bent back with a pair of pliers before the tripod can be removed. Under normal conditions it is not necessary to secure the GKN rollers to their studs during separation due to the presence of a retainer ring on the end of each stud. This retention force can easily be overcome if the rollers are pulled or impacted. It is also possible to pull the rollers off by removing or installing the tripod with the connecting shaft at too high an angle, relative to the housing.
  2.  
  3. Remove the snapring from the shaft end groove, then remove the tripod with a brass punch.
  4.  

To install:
  1. Remove as much grease as possible from the assembly. Look at the ball housing races, and the components for excessive wear.
  2.  

DO NOT CLEAN THE INNER HOUSING WITH MINERAL SPIRITS OR SOLVENT. Solvents will destroy the rubber seals that are hidden in the housing and permit grease leakage. If wear is excessive, replace as necessary.

  1. Fasten the new boot onto the interconnecting shaft. Install the tripod on the shaft as follows:
    1. GKN type: slide the tripod onto the shaft with the non-chamfered end facing the tripod retaining ring groove.
    2.  
    3. Citroen type: slide the tripod onto the shaft (both sides are the same).
    4.  

  2.  
  3. Install the retainer snapring into the groove on the interconnecting shaft locking the tripod in position.
  4.  
  5. On GKN type: put two of the three packets of grease into the boot and the remaining pack into the housing. On Citroen type: put two thirds of the packet of grease into the boot and the remaining grease into the housing.
  6.  
  7. Position the spring into the housing spring pocket with the cup attached to the exposed end of the spring. Place a small amount of grease in the spring cup.
  8.  
  9. On G.K.N type: slip the tripod into the housing and bend down the retaining tabs. Make sure the tabs are holding the housing firmly.
  10.  
  11. On Citroen type: remove the tape holding the rollers and needle bearings in place. Hold the rollers and needles in place and install the housing.
  12.  
  13. Install the retaining ring into the machined groove in the housing with a punch and plastic hammer. Hold the retaining collar in position with two C-clamps while engaging the retainer ring.
  14.  


WARNING
When installing the tripod, the spring must be centered in the housing to insure proper positioning.

  1. Position the boot over the retaining groove in the housing and clamp in position.
  2.  

Outer Joint

See Figures 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37 and 38



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Fig. Fig. 27: Removing the housing boot clamp-1987 Voyager with Citroen type CV-joint



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Fig. Fig. 28: Removing the shaft boot clamp



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Fig. Fig. 29: After removing the clamps, pull the the boot back from the housing



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Fig. Fig. 30: Use a soft hammer and tap on the joint body to dislodge it from the internal circlip



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Fig. Fig. 31: Removing the inner housing and shaft from the interconnecting shaft



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Fig. Fig. 32: Slide the boot and grease from the shaft



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Fig. Fig. 33: Rotate the cage and cross to remove the balls



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Fig. Fig. 34: Removing the balls from the joint



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Fig. Fig. 35: Removing the case and cross assembly from the housing



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Fig. Fig. 36: Lubricate the ball races of the joint



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Fig. Fig. 37: Gently tap the outer shaft and housing with a soft hammer onto the interconnecting shaft



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Fig. Fig. 38: After filling the new boot with the correct amount of grease install the boot retaining clamps

  1. Remove the boot clamps and discard them.
  2.  
  3. Wipe away the grease to expose the joint.
  4.  
  5. Support the shaft in a vise (Cushion the vise jaws to prevent shaft damage).
  6.  
  7. Hold the outer joint, and using a plastic hammer, give a sharp tap to the top of the joint body to dislodge it from the internal circlip.
  8.  
  9. If the shaft is bent carefully pry the wear sleeve from the CV-joint machined ledge.
  10.  
  11. Remove the circlip from the shaft and discard it.
  12.  

Replacement boot kits will contain this circlip.

  1. Unless the shaft is damaged do not remove the heavy spacer ring from the shaft.
  2.  

If the shaft must be replaced, care must be taken that the new shaft is of the proper construction, depending on whether the inner joint is spring loaded or not. If the CV-joint was operating satisfactorily, and the grease down not appear contaminated, just replace the boot. If the outer joint is noisy or badly worn, replace the entire unit. The repair kit will include boot, clamps, retaining ring (circlip) and lubricant.

  1. Wipe off the grease and mark the position of the inner cross, cage and housing with a dab of paint.
  2.  
  3. Hold the joint vertically in a vise. Do not crush the splines on the shaft.
  4.  
  5. Press down on one side of the inner race to tilt the cage and remove the balls from the opposite side.
  6.  
  7. If the joint is tight, use a hammer and brass drift pin to tap the inner race. Repeat this step until all balls have been removed. DO NOT hit the cage.
  8.  
  9. Tilt the cage and inner race assembly vertically and position the two opposing, elongated cage windows in the area between the ball grooves. Pull the cage out of the housing.
  10.  
  11. Turn the inner cross 90° and align the race lands with an elongated hole in the cage. Remove the inner race.
  12.  

To install:
  1. Position a new wear sleeve on the joint housing and install it using a suitable driver. Lubricate all of the components before assembly.
  2.  
  3. Align the parts according to paint markings.
  4.  
  5. Install one of the inner race lands into the cage window and feed the race into the cage.
  6.  
  7. Turn the cross 90° and align the opposing cage windows with the land, pivot another 90° and complete the land installation.
  8.  
  9. When properly installed, the cross counter bore should be facing outward from the joint on GKN type. The cross and cage chamfers will be facing out on Citroen type.
  10.  
  11. Apply the grease to the ball races. Install the balls into the raceway by tilting the cage and inner race assembly.
  12.  
  13. Fasten the boot to the shaft and install the new retainer circlip provided.
  14.  
  15. Position the outer joint on the splined end of the stub shaft and engage the splines and tap sharply to engage the circlip. Attempt to pull the shafts apart to see if the circlip is properly seated.
  16.  
  17. Position the large end of the boot and secure with a clamp and install the halfshaft.
  18.  

 
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