Chrysler Colt/Vista 1990-1993 Repair Information

Intermediate Shaft Constant Velocity Joints

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OVERHAUL



Two types of CV joints are used on each shaft. On the inner end of the shaft is a Birfield joint; on the outer end, a double offset joint. The DOJ can be disassembled; the Birfield joint cannot. CV joint repair kits are the only way to rebuild the joint. These kits come with a special grease. Use it.

  1. Remove the boot bands.
  2.  
  3. Remove the circlip from the DOJ outer race.
  4.  
  5. Separate the intermediate shaft from the DOJ outer race.
  6.  
  7. Remove the balls from the DOJ cage.
  8.  
  9. Remove the cage from the inner race, in the direction of the Birfield joint.
  10.  
  11. Remove the snapring from the shaft and pull the DOJ inner race and cage from the shaft. Remove the circlip.
  12.  
  13. Wrap plastic tape around the splines on the shaft and slide the boots off. Pay attention to the boots, they are different from each other. Be sure to use the correct boot for each end when installing them.
  14.  
  15. Clean all parts in a non-flammable solvent. Check all parts for wear or damage. Replace any suspect parts. If the Birfield joint is defective, the shaft and joint must be replaced as an assembly.
  16.  
  17. Apply the special grease to the intermediate shaft and install the boots and bands. Be sure to install the different boots to their correct shaft end.
  18.  
  19. Install the cage onto the shaft, smaller end first.
  20.  
  21. Install the circlip.
  22.  
  23. Install the inner race and snapring.
  24.  
  25. Coat the inner race and cage with the special grease and fit them together.
  26.  
  27. Apply the special grease to the balls and insert them into the cage and race.
  28.  
  29. Apply about 2.5 ounces of the special grease to the outer race.
  30.  
  31. Insert the shaft into the outer race and apply another 2.5 ounces of grease on the race.
  32.  
  33. Install the circlip on the outer race.
  34.  
  35. Position the boot over the DOJ and secure it with the band.
  36.  
  37. Install the smaller band and position it so that 76mm exists between the two bands. Tighten the band.
  38.  
  39. Pack the Birfield joint with 4-5 ounces of the special grease.
  40.  

 
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