Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Halfshafts

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REMOVAL & INSTALLATION



See Figures 1 through 7

If the vehicle is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or proper equivalent tools and install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cotter pin, nut lock and spring washer.
  4.  
  5. Loosen, but do not remove, the halfshaft nut while the vehicle is on the floor with the brakes applied.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the wheel.
  10.  
  11. Remove the brake caliper assembly and support it from the strut coil using a strong piece of wire.
  12.  
  13. Remove the brake rotor.
  14.  
  15. Remove the halfshaft nut and washer.
  16.  



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Fig. Fig. 1: Remove the cotter pin from the outer CV-joint stub shaft



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Fig. Fig. 2: Remove the nut lock and spring washer from the CV-joint stub shaft



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Fig. Fig. 3: Loosen the hub nut with the vehicle on the floor and the brakes applied



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Fig. Fig. 4: After removing the wheel and brake hardware, remove the axle shaft nut and washer



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Fig. Fig. 5: Pulling the steering knuckle away from the stub shaft



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Fig. Fig. 6: Place a prybar between the tripod joint housing and transaxle and pry outward



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Fig. Fig. 7: Support the halfshaft assembly and slide it out of the vehicle

  1. Using joint separation tool MB991113 or equivalent, disconnect the tie rod end from the steering knuckle.
  2.  


WARNING
Use of improper methods of joint separation can result in damage to the joint, leading to possible failure.

  1. If equipped with an Anti-lock Brake System (ABS), remove the speed sensor cable routing bracket.
  2.  
  3. If necessary, disconnect the sway bar link from the damper fork.
  4.  
  5. Remove the damper fork lower through-bolts and upper pinch bolt. Remove the damper fork assembly.
  6.  
  7. Using a joint separation tool, disconnect the steering knuckle from the lower control arm.
  8.  
  9. Remove the halfshaft from the hub/knuckle by setting up a puller on the outside wheel hub, if necessary, and pressing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.
  10.  

Do not pull on the shaft. Doing so damages the inboard joint. Do not insert the prybar too far, or the oil seal in the case may be damaged.

To install:
  1. Inspect the halfshaft boot for damage or deterioration. Check the ball joints and splines for wear.
  2.  
  3. Replace the circlips on the ends of the halfshaft(s).
  4.  
  5. Insert the halfshaft into the transaxle. Make sure it is fully seated.
  6.  
  7. Pull the knuckle assembly outward and install the other end of the halfshaft into the hub.
  8.  
  9. Install the washer so the chamfered edge faces outward. Install the halfshaft nut and tighten temporarily.
  10.  
  11. Connect the control arm to the steering knuckle. Tighten the self-locking nuts to 43-52 ft. lbs. (59-71 Nm).
  12.  
  13. Install the damper fork. Tighten the lower through-bolt/nut to 65 ft. lbs. (88 Nm) and the upper pinch bolt to 76 ft. lbs. (103 Nm).
  14.  
  15. Connect the tie rod end to the steering knuckle. Tighten the retaining nut to 17-25 ft. lbs. (24-33 Nm) and install a new cotter pin.
  16.  
  17. Connect the sway bar link to the damper fork and tighten the link nut to 29 ft. lbs. (39 Nm).
  18.  
  19. Install the lockwasher and axle nut. Tighten the axle nut to 145-188 ft. lbs. (200-260 Nm).
  20.  

Before securely tightening the axle nut, make sure there is no load on the wheel bearings.

  1. Install the brake rotor and caliper assembly.
  2.  
  3. Install a new cotter pin and bend to secure.
  4.  
  5. Install the wheel.
  6.  
  7. Check the transaxle fluid level, and top off if necessary.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Test drive the vehicle and check for proper operation.
  12.  

CV-JOINT OVERHAUL



The only service that can be performed on the halfshaft assemblies is to replace the driveshaft seal boots.

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 8 through 15

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.



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Fig. Fig. 8: After discarding the boot clamps, remove the tripod joint housing from the interconnecting shaft and spider assembly



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Fig. Fig. 9: Location of the spider assembly's retaining snapring



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Fig. Fig. 10: 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.

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Fig. Fig. 11: Installation of the sealing boot on the interconnecting shaft



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Fig. Fig. 12: Tighten the nut on the crimping tool until the jaws are completely closed, face-to-face



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Fig. Fig. 13: 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.  



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Fig. Fig. 14: When installing a latching-type boot clamp, position a suitable clamp locking tool on the clamp as shown ...



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Fig. Fig. 15: ... 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 16, 17 and 18

  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.  
  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.
    6.  

  8.  



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Fig. Fig. 16: Remove the circlip from the shaft using a pair of snapring pliers

  1. 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.
  2.  
  3. Slide the faulty boot off the interconnecting shaft.
  4.  
  5. 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.
  6.  

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.  



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Fig. Fig. 17: If necessary, use a soft faced hammer to install the outer C/V joint to the interconnecting shaft



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Fig. Fig. 18: 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.  

 
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