Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Halfshafts

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IDENTIFICATION



Refer to the necessary illustrations on later model vehicles to identify each driveshaft (halfshaft) assembly. Vehicles can be equipped with any of these driveshafts (halfshaft) assemblies. Chrysler front wheel drive vehicles use two different driveshaft systems. Some vehicles use an equal length system while other vehicles use an unequal length system (refer to the illustration).

Except Premier and Monaco

See Figures 1, 2 and 3

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.



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Fig. Fig. 1: The various types of CV-joints and halfshaft assemblies can be identified by numerous differences as shown



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Fig. Fig. 2: The 2 types of halfshaft systems can easily be identified by the extra intermediate shaft and Cardan joint

The halfshaft assemblies are three piece units. Each shaft has an inner sliding constant velocity (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 and 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.

It is impossible to classify the specific driveshaft type according to model and year designations. However, each type of shaft is clearly identifiable according to the design features pointed out on the enclosed illustrations. Use these to classify the joint according to brand and type so that if parts are to be replaced, you can order by manufacturer name as well as the year and model of the car.



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Fig. Fig. 3: Exploded view of the halfshaft components, showing their positions relative to one another

Premier and Monaco

The halfshafts are comprised of an inner CV-joint, an interconnecting shaft and an outer Rzeppa CV-joint with a stub shaft. The inner tripod CV-joint can be disassembled but must be replaced as a unit. The outer Rzeppa joint CV-joint cannot be disassembled and must be replaced as a unit. The protective rubber boots and clamps that cover each CV-joint are replaceable components.

REMOVAL & INSTALLATION



1988 Models
  1. Drain the transaxle fluid as described in General Information & Maintenance . Bend the cotter pin straight and pull it out of the end of the driveshaft. Then, unscrew and remove the nut lock. Remove the spring washer.
  2.  
  3. Have someone apply the brakes and, with the car still resting on the wheels, loosen the hub nut and the wheel nuts.
  4.  
  5. Raise the vehicle and support it securely by the body. Remove the wheel nuts and wheel. Remove the hub nut and the washer.
  6.  
  7. If removing the right side driveshaft, remove the single attaching bolt and pull the speedometer pinion out of the transaxle case.
  8.  

Do not pry against the ball joint or CV-joint boots in the next step.

  1. Remove the nut and bolt clamping the ball joint stud into the steering knuckle. Then, carefully (to avoid damaging the ball joint or CV-joint boot) use a small prybar to pry the lower control arm ball joint stud out of the steering knuckle.
  2.  

Be careful not to pry against or otherwise use excessive force on the wear sleeve of the CV-joint as you perform the following step.

  1. Hold the outer CV-joint housing with one hand and use the other to move the hub and knuckle assembly outward to pull the outer joint shaft out of the hub.
  2.  
  3. Support the driveshaft assembly at both CV-joint housings.
  4.  

The axle must be supported at both CV-joints during this operation to avoid pulling on the shaft. Any stretching forces may damage the U-joints!

Then, pull on the inner joint housing in order to pull it out of the transaxle.

Note that the driveshaft, when in its normal, installed position, acts to keep the hub/bearing assembly in place. If the vehicle is to be supported by its wheels or moved on them while the driveshaft is out of the car, install a bolt through the hub to ensure the hub bearing assembly cannot loosen.

To install:
  1. Thoroughly clean the seal located between the outer end of the driveshaft and the steering knuckle with a safe solvent. Make sure solvent does not get onto the driveshaft boot. Apply a bead of a lubricant such as Mopar Multipurpose Lubricant® Part No. 4318063 or the equivalent. Apply it to the full circumference and make the bead 1 / 4 in. (6mm) wide. Fill the lip-to-housing cavity on the seal around its complete circumference; wet the seal lip with the lubricant, as well.
  2.  
  3. To install the driveshaft assembly, first inspect units on turbocharged cars to make sure the rubber washer seal is in place on the right inner joint. Relocate the seal, if necessary.
  4.  
  5. Support the driveshaft by both CV-joints. Hold the inner joint assembly at the housing. Align the splined joint with the splines in the differential side gear, guide it into the housing, and insert it until it locks.
  6.  

If installing an A.C.I. brand shaft, make sure the tripod joint engages in the housing and is not twisted.

  1. If necessary, remove the bolt installed through the hub earlier. Push the hub and knuckle assembly outward and insert the outer splined CV-joint shaft into the hub. Then, insert the ball joint stud into the knuckle assembly. Install the clamp bolt and nut and tighten to 70 ft. lbs. (95 Nm).
  2.  

Note that, if replacing the the clamp bolt, it is a prevailing torque type and must be replaced with an equivalent part.

  1. If it has been removed, insert the speedometer pinion back into the transaxle with the bolt hole in the retaining collar aligned with the threaded hole in the transaxle. Install the retaining bolt.
  2.  
  3. Install the specified lubricant into the transaxle.
  4.  
  5. Install the wheel and wheel nuts. Lower the car to the floor. Clean the hub nut threads, located at the outer end of the shaft. Install the washer and then install the nub nut. Tighten the hub nut to 180 ft. lbs. (245 Nm).
  6.  
  7. Install the lock finger tight. Then, back it off until the cotter pin slot aligns with the hole in the end of the driveshaft. Install the cotter pin until it is pulled all the way through. Bend the prongs tightly around the outer end of the nut lock. Make sure the prongs wrap tightly. Tighten the wheel nuts to 95 ft. lbs. (130 Nm).
  8.  
  9. If the boot on the transaxle end of the shaft is deformed (collapsed), it must be vented and restored to its normal shape. To do so, first remove and discard the clamp on the shaft side (if the shaft has one); then, insert a round, small diameter rod between the boot and the shaft to vent it; then, work the boot back into its normal shape, being careful to keep dirt from getting in or grease from getting out. When the boot has reached its normal shape, remove the rod and install a new service clamp.
  10.  

1989-95 Models

See Figures 4 through 11



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Fig. Fig. 4: Before removing the halfshafts, unplug the speed sensor wiring connector ...

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  

Do not roll the vehicle with halfshafts removed from the vehicle.

  1. Remove the tire and wheel assembly.
  2.  



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Fig. Fig. 5: ... unbolt the sensor and pull it out of the transaxle, making sure ...

  1. Remove the cotter pin from the end of the halfshaft. Remove the nut lock, spring washer, axle nut and washer.
  2.  
  3. Remove the ball joint retaining bolt and pry the control arm down to release the ball stud from the steering knuckle.
  4.  
  5. Position a drain pan under the transaxle where the halfshaft enters the differential or extension housing. Remove the halfshaft from the transaxle or center bearing. Unbolt the center bearing from the block and remove the intermediate shaft from the transaxle, if equipped.
  6.  



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Fig. Fig. 6: ... to retain the drive gear on the end of the sensor



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Fig. Fig. 7: Loosen and remove the lower ball joint cinch bolt ...



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Fig. Fig. 8: ... then pry the lower control arm and ball joint out of the steering knuckle



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Fig. Fig. 9: Have an assistant pull the hub and knuckle assembly off of the outer end of the halfshaft



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Fig. Fig. 10: Support the outer end of the halfshaft while pulling the halfshaft assembly out of the transaxle ...



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Fig. Fig. 11: ... then remove the halfshaft assembly from the vehicle

To install:
  1. Install the halfshaft or intermediate shaft to the transaxle, being careful not to damage the side seals. Make sure the inner joint clicks into place inside the differential. Install the center bearing retaining bolts if equipped, then install the outer shaft to the center bearing.
  2.  
  3. Pull the front strut out and insert the outer joint into the front hub.
  4.  
  5. If necessary, turn the ball joint stud to position the bolt retaining indent to the inside of the vehicle. Install the ball joint stud into the steering knuckle. Install the retaining bolt and nut and tighten to 70 ft. lbs. (95 Nm).
  6.  

This nut and bolt combination is unique to this application and should not be replaced with conventional hardware! Use original equipment parts if replacing!

  1. Install the axle nut washer and nut and tighten the nut to 180 ft. lbs. (244 Nm). Install the spring washer, nut lock and a new cotter pin.
  2.  
  3. Install the tire and wheel assembly.
  4.  

Premier and Monaco

The halfshafts are comprised of an inner CV-joint, an interconnecting shaft and an outer Rzeppa CV-joint with a stub shaft. The inner tripod CV-joint can be disassembled but must be replaced as a unit. The outer Rzeppa joint CV-joint cannot be disassembled and must be replaced as a unit. The protective rubber boots and clamps that cover each CV-joint are replaceable components.

  1. Disconnect the negative battery cable. Raise the vehicle and support safely.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake caliper but do not disconnect the brake hose from the caliper. Wire it aside. Do not allow the brake hose to support the weight of the caliper.
  6.  
  7. Remove the halfshaft hub nut. A holding fixture may be required to hold the wheel hub/rotor when removing the nut.
  8.  
  9. Spiral wound roll pin(s) are used to retain each halfshaft at the transaxle. Using a drift type tool, remove the halfshaft-to-transaxle roll pin(s).
  10.  

Before proceeding to the next step, be certain the front suspension is hanging free. The strut body to suspension knuckle bolts are splined. Remove the bolts only as instructed in the following steps.

  1. Remove the 2 splined bolts that attach the strut body to the suspension knuckle. Do this by first loosening and turning the nuts (do not turn the bolt heads) until they are almost at the end of the bolt threads. Tap the nuts with a brass hammer to loosen the bolts and disengage the splines. Remove the nuts and slide the bolts out of the strut body and suspension knuckle.
  2.  
  3. Place a drain pan under the transaxle end of the halfshaft.
  4.  
  5. Wrap a shop towel around the halfshaft outer rubber boot to prevent damaging the boot.
  6.  
  7. Tilt the suspension knuckle out and away from the strut body and remove the halfshaft. If the halfshaft cannot be pushed through the hub by hand, use a puller.
  8.  

To install:
  1. Install the halfshaft to the transaxle shaft and align the roll pin holes in each shaft.
  2.  

One side of the roll pin hole in the transaxle shaft is beveled. Align the beveled side of that hole with the side of the hole in the CV-joint housing that is located in the housing "valley.''

  1. Insert the roll pin(s) and seat with a hammer and a drift type tool.
  2.  
  3. Insert the halfshaft end through the hub.
  4.  
  5. Tilt the knuckle back into position and install the bolts. Hold the bolt heads with a wrench to prevent them from turning and tighten the nuts to 123 ft. lbs. (167 Nm).
  6.  
  7. Install the halfshaft end nut and tighten to 181 ft. lbs. (245 Nm), while holding the rotor and hub in place.
  8.  
  9. Install the brake caliper.
  10.  
  11. Check the differential fluid level. Fill with recommended synthetic gear oil.
  12.  
  13. Install the wheels.
  14.  
  15. Connect the negative battery cable.
  16.  

CV-JOINT OVERHAUL



Inner CV-Joint
DISASSEMBLY

See Figures 12 and 13

With the driveshaft assembly removed from the vehicle, identify the unit type from the illustrations.

  1. Remove the boot clamps and pull the boot back to gain access to the tripod retention system, which prevents accidental separation from the CV-joint housing.
  2.  

When removing the housing from the tripod, hold the rollers in place on the trunnion studs to prevent the rollers and needle bearings from falling away. After the tripod is out of the housing, secure the rollers in place with tape.

  1. Depending on the type of CV-joint assembly, separate the tripod from the housing as follows:
    1. S.S.G. -Utilizes a wire ring tripod retainer which expands into a groove around the top of the housing. Use a flat head prytool to pry the wire ring out of the groove and slide the tripod from the housing. Do not mangle or destroy the retainer during disassembly.
    2.  
    3. G.K.N. -The retention system on this assembly is a integral part of the plastic collar on the inside of the CV-joint housing. Clamp the stub shaft of the CV-joint housing in a vise and use protective caps or the equivalent on the jaws of the vise to prevent damage to the stub shaft. Hold the interconnecting shaft on an angle, while gently pulling on the shaft until one of the tripod bearings is free of the retaining collar. Continue holding the interconnecting shaft on an angle and gently pull on the shaft until all rollers are free of the retaining collar.

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      Fig. Fig. 12: Use a small prytool to remove the retaining spring from the housing-S.S.G. type inner CV-joints



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      Fig. Fig. 13: When removing the inner tripod joint, make certain to use soft jaws (or equivalent) on the vise to prevent damage to the shaft-G.K.N. types

    4.  

  2.  

TRIPOD REMOVAL FROM INTERCONNECTING BAR

See Figures 14, 15, 16 and 17

  1. For S.S.G. CV-joints, remove the snap ring from the shaft end-groove. Remove the tripod by hand or by tapping the body with a brass punch.
  2.  



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Fig. Fig. 14: Carefully use a brass punch or drift to remove the tripod joint from the shaft-S.S.G. type inner CV-joints

  1. For G.K.N. CV-joints, perform the following:
    1. Expand the stop ring behind the tripod and slide it back along the shaft.
    2.  
    3. Slide the tripod back along the shaft, either by hand or by tapping the body with a brass drift. This will expose the circlip on the end of the interconnecting bar.
    4.  
    5. Remove the circlip from the end of the interconnecting bar.
    6.  
    7. Remove the tripod from the interconnecting bar. It is not necessary to remove the stop ring from the interconnecting bar unless the bar is being replaced.

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      Fig. Fig. 15: Use a pair of snapring pliers to slide the inner ring down the shaft, then tap the tripod joint down the shaft ...



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      Fig. Fig. 16: ... after which the outer circlip can be removed from the end of the shaft



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      Fig. Fig. 17: Once the tripod joint has been removed from the shaft, both the stop ring and circlip grooves can be seen easier

    8.  

  2.  

INSPECTION OF TRIPOD AND HOUSING

Remove as much grease as possible from the assembly. Inspect the joint housing ball raceway and tripod components for excessive wear, replace if needed.

Inspect the spring, spring cup and the spherical end of the connecting shaft for excessive wear or damage, replace with new components if needed.

ASSEMBLY
  1. For G.K.N. CV-joints, perform the following:
    1. Slide the rubber washer seal over the stub shaft and down into the groove provided. The rubber washer seal is used only on the right inner CV-joint on the equal length drive shaft systems.
    2.  
    3. Fasten the boot to the interconnecting shaft. For more details, refer to the CV-joint boot procedure.
    4.  
    5. Slide the stop ring back into the stop ring groove on the interconnecting bar.
    6.  
    7. Install a new circlip in the circlip groove on the interconnecting bar.
    8.  
    9. With the chamfered end of the tripod facing the stop ring, align the tripod splines and push or tap on the body of the tripod assembly with a soft drift, until the tripod is seated on the shaft. Check to make sure that the tripod is fully installed by attempting to pull the tripod off of the shaft by hand.
    10.  

  2.  
  3. For S.S.G. CV-joints, perform the following steps:
    1. Slide the washer seal over the stub shaft and down into the groove provided. The rubber washer seal is used only on the right inner CV-joint on the equal length drive shaft systems.
    2.  
    3. Fasten the boot to the interconnecting shaft. For more details, refer to the CV-joint boot procedure.
    4.  
    5. Install the first wire ring tripod retainer over the interconnecting shaft, slide the tripod on the shaft (both ends are the same).
    6.  
    7. Install the snapring into the groove on the interconnecting shaft to lock the tripod in position.
    8.  

  4.  
  5. If the wire ring tripod retainer is not suitable for reuse and a new one is not available, the following procedure should be used:
    1. Install the tripod on the interconnecting shaft.
    2.  
    3. Install the spring and cup assembly into the inner joint housing.
    4.  
    5. Position the small end of the boot in the locating grooves on the interconnecting shaft.
    6.  
    7. Clamp the small end of the boot clamp onto the boot, thereby retaining the boot to the interconnecting shaft.
    8.  
    9. Distribute 1 / 2 packet of the CV-joint rebuild grease into the boot and 1 / 2 into the housing.
    10.  
    11. Install the tripod into the housing.
    12.  
    13. Place the large clamp over the shaft.
    14.  
    15. Install the halfshaft into the vehicle.
    16.  
    17. Position the large end of the boot into the locating groove.
    18.  
    19. Slide the large clamp into position.
    20.  
    21. For boot clamping instructions, refer to the CV-joint boot procedure later in this section.
    22.  

  6.  

INNER CV-JOINT HOUSING INSTALLATION
  1. For the G.K.N. CV-joints, perform the following steps:
    1. Distribute 1 / 2 of the lubricant provided in the CV-joint rebuild kit into the housing and the remaining amount into the boot.
    2.  
    3. Position the spring in the housing spring pocket with the spring cup attached to the exposed end of the spring. Place a small amount of grease on the concave surface of the spring cup.
    4.  

  2.  

Care must be taken to ensure proper spring positioning. The spring must remain centered in the housing spring pocket when the tripod is installed and seated in the spring cup.

  1. Clamp the stub shaft of the housing in a vise. Use protective caps (or the equivalent) on the jaws of the vise so that the stub shaft does not get damaged by the vise. Position the interconnecting shaft and the tripod assembly on top of the plastic retaining collar. Carefully insert each of the tripod rollers into the retaining collar, one at a time while holding the interconnecting shaft on an angle. Carefully push down on the shaft until the rollers are locked into the retaining collar in the housing.
  2.  
  3. Position the boot over the boot retaining groove in the housing and clamp in place. For more details, refer to the CV-joint boot installation procedure later in this section.
  4.  

  1. For the S.S.G. type CV-joints, use the following steps:
    1. Distribute 1 / 2 of the lubricant provided in the CV-joint rebuild kit into the housing and the remaining amount into the boot.
    2.  
    3. Position the spring in the housing spring pocket with the spring cup attached to the exposed end of the spring. Place a small amount of grease on the concave surface of the spring cup.
    4.  

  2.  

Care must be taken to ensure proper spring positioning. The spring must remain centered in the housing spring pocket when the tripod is installed and seated in the spring cup.

  1. Slip the tripod into the housing and install the tripod wire retaining ring into position. Check for the ability of the retaining ring to hold the tripod in the housing.
  2.  
  3. Position the boot over the boot retaining groove in the housing and clamp in place. For more details, refer to the CV-joint boot installation procedure later in this section.
  4.  

Outer CV-Joint

DISASSEMBLY

See Figures 18 and 19

  1. Remove the boot clamps and boot, then discard the old boot.
  2.  
  3. Wipe away the grease to expose the joint.
  4.  
  5. For G.K.N. type CV-joints, remove the CV-joint from the shaft by supporting the interconnecting shaft in a vise. Use protective caps (or the equivalent) on the jaws of the vise so that the stub shaft does not get damaged by the vise. Give a sharp tap with a rubber or plastic mallet to the top of the housing to dislodge the joint from the internal circlip installed in a groove at the outer end of the shaft.
  6.  



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Fig. Fig. 18: An exploded view of the outer CV-joint components

  1. In S.S.G. type CV-joints, a single circlip located in a groove on the cross and is used to retain the cross to the shaft. Loosen the damper weight bolts and slide it and the boot toward the inner CV-joint. Expand the circlip and with snapring pliers and slide the joint off of the shaft. Reinstall the damper weight onto the shaft.
  2.  



Click image to see an enlarged view

Fig. Fig. 19: This single circlip is used to retain the cross to the shaft-use snapring pliers to expand the circlip

WEAR SLEEVE

See Figures 20, 21, 22 and 23

A wear sleeve installed on the outer CV-joint housing provides a wipe surface for the hub bearing seal (installed in the steering knuckle).

  1. If bent or damaged, carefully pry the wear sleeve from the CV-joint machined ledge.
  2.  
  3. Remove the circlip from the shaft groove and discard. A replacement boot package should include a new circlip.
  4.  
  5. Unless the shaft is damaged and needs to be replaced, do not remove the heavy spacer ring from the shaft (G.K.N. types only).
  6.  
  7. With the joint separated from the interconnecting shaft proceed as follows:
    1. If the outer CV-joint was operating satisfactorily and grease does not appear to be contaminated, just replace the boot with a new one. Bypass the following disassembly procedure for the CV-joint assembly.
    2.  
    3. If the outer joint is noisy or badly worn, bypass the following disassembly procedure and replace the entire unit with a new one. It is also recommended that the boot be replaced with a new one. The boot package from Chrysler includes the boot, clamps, retaining ring (circlip) and lubricant.
    4.  

  8.  
  9. Hold the joint vertically in a vise by clamping the splined shaft, using soft jaws (or equivalent) to prevent damage.
  10.  
  11. Wipe off surplus grease and mark the relative position of the inner cross, cage and housing with a dab of paint.
  12.  
  13. Press down on one side of the inner race to tilt the cage and remove the ball from the opposite side. If the joint is tight, use a hammer and brass drift to tap the inner race. Do not hit the cage. Repeat this step until all 6 balls are removed. A small prytool may be used to pry the balls loose.
  14.  



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Fig. Fig. 20: Before disassembly, make certain to matchmark the housing, the cage and the cross (driver) for reassembly



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Fig. Fig. 21: Remove each ball, one at a time, until all have been removed ...

  1. Tilt the cage and inner race assembly vertically and position the two opposing cage windows in the area between the ball grooves. Remove the cage and inner race assembly by pulling upward and away from the housing.
  2.  



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Fig. Fig. 22: ... then remove the cage by turning it 90° on its side and pulling it out of the housing



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Fig. Fig. 23: The cross (driver) is removed from the cage in the same manner as the cage was removed from the housing

  1. Turn the inner cross (driver) 90° to the cage and align one of the race spherical lands with the cage window. Raise the land into the cage window and remove the inner race by swinging it out.
  2.  

INSPECTION

Check the grease for contamination and all parts for defects as follows:

  1. Wash all parts in a suitable solvent and dry, preferably with compressed air.
  2.  
  3. Inspect the housing ball races for excessive wear and scratching.
  4.  
  5. Check the splined shaft and nut threads for damage.
  6.  
  7. Inspect all 6 balls for pitting, cracks, scoring and wear. Dulling of the balls' surface is normal.
  8.  
  9. Inspect the cage for excessive wear on the inside and outside spherical surfaces, surface ripples on the cage window, cracks and chipping.
  10.  
  11. Inspect the inner race (cross) for excessive wear or scoring of the ball races.
  12.  

Any of the previous defects warrants the replacement of the CV-joint assembly as a unit.

Polished areas in races (cross and housing) and on cage spheres are normal and do not indicate need for joint replacement.

ASSEMBLY

See Figure 24

If neither the outer joint was disassembled nor the wear sleeve damaged, go to Step 9.

  1. Position the new wear sleeve on the joint housing machined ledge. Assemble the installation tool (Special Tool C-4698 or the equivalent), which is provided with a handle and dual purpose drive head for installing the wear sleeve onto the CV-joint housing and seal into the knuckle.
  2.  
  3. Install the wear sleeve with the installation tool.
  4.  



Click image to see an enlarged view

Fig. Fig. 24: This tool (or the equivalent) is necessary for the installation of the wear sleeve-do not try to install it with a hammer and drift

  1. Lightly oil all components before assembling the outer joint.
  2.  
  3. Align all components according to the paint markings.
  4.  
  5. Insert one of the inner race (cross) lands into the cage window and feed the race into the cage. Pivot the cross 90° to complete the cage assembly.
  6.  
  7. Align the opposing cage windows with the housing land and feed the cage assembly into the housing. Pivot the cage 90° to complete the installation.
  8.  

When properly assembled, the large counterbore in the cross should be facing outward from the joint on the G.K.N. units. On the S.S.G. joint the internal circlip in the cross will be facing outward from the housing.

  1. Apply lubricant to the ball races from the packet provided in the boot kit and distribute equally between all sides of the ball grooves. One packet is sufficient to lubricate the joint.
  2.  
  3. Insert the balls into the raceway by tilting the cage and inner race assembly.
  4.  
  5. Fasten the boot to the shaft. For more details, refer to the boot installation procedure later in this section.
  6.  
  7. On G.K.N. units, insert the new circlip, provided with the kit, in the shaft groove. Do not over expand or twist the circlip during installation. The S.S.G. unit has a reusable circlip retainer that is an integral part of the driver assembly.
  8.  
  9. Position the outer joint on the splined end with the hub nut on the stub shaft. Engage the splines, then tap sharply with the plastic or rubber mallet.
  10.  
  11. Check that the circlip is properly seated by attempting to pull the joint from the shaft.
  12.  
  13. Locate the large end of the boot over the joint housing checking that the boot is not twisted.
  14.  
  15. Fasten the boot to the housing. For more details, refer to the boot installation procedure.
  16.  

CV-Joint Boots

HANDLING AND CLEANING

It is vitally important during any service procedures requiring boot handling, that care be taken not to puncture or tear the boot by over tightening the clamps, misuse of tools or pinching the boot. Pinching can occur by rotating the CV-joint beyond normal working angles.

The halfshaft boots are not compatible with oil, gasoline or cleaning solvents. Care must be taken that boots never come in contact with any of these liquids.

The only acceptable cleaning agent for the halfshaft boots is soap and water. After washing, the boots must be thoroughly rinsed and dried before reusing.

INSPECTION

Noticeable amounts of grease on areas adjacent to or on the exterior of the CV-joint boot, is the first indication that a boot is punctured, torn or that a clamp has loosened. When a CV-joint is removed for servicing of the joint. The boot should be properly cleaned and inspected for cracks, tears and scuffed areas on the interior surfaces. If any of these conditions exist, boot replacement is necessary.

INSTALLATION-RUBBER BOOTS

See Figures 25 through 33


WARNING
The hard plastic boots require approximately 100 times the clamping force of the rubber boot. The clamps used on the rubber boots do not have the type of load capacity required to seal the hard plastic boots and should not be used for this purpose.

Rubber boots appear only on the inner joints of certain halfshafts. The rubber boots must be serviced with the strap and buckle clamp. Use the clamp installation tool (Special tool C-4653 or the equivalent).

  1. Slide the small end of the boot over the shaft. Position the boot to the edge of the locating mark or groove, whichever is appropriate.
  2.  
  3. Install the CV-joint. For more details, refer to the CV-joint installation procedures earlier in this section.
  4.  



Click image to see an enlarged view

Fig. Fig. 25: The small end of the CV-joint boot should be positioned as shown-G.K.N. type CV-joints

  1. Slide the large diameter of the boot into the locating groove.
  2.  
  3. Wrap the binding strap around the boot twice, plus an additional 2 1 / 2 in. (63mm).
  4.  



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Fig. Fig. 26: Wrap the strap around the large end of the boot 2 times, plus an additional 21/2 in. (63mm) and cut off the excess

  1. Pass the strap through the buckle and fold it back about 1 1 / 8 in. (29mm) on the inside of the buckle.
  2.  
  3. Put the strap around the boot with the eye of the buckle toward you. Wrap the strip around the boot once and pass it through the buckle, then wrap it around a second time also passing it through the buckle.
  4.  
  5. Fold the strip back slightly to prevent it from slipping backwards.
  6.  



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Fig. Fig. 27: Unwrap the strap from the boot, then install the buckle over one end of the strap as shown



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Fig. Fig. 28: Wrap the strap around the boot once and insert it through the buckle, then ...

  1. Open the tool all the way and place the strip in the narrow slot approximately 1 / 2 in. (13mm) from the buckle.
  2.  
  3. Hold the binding strip with the left hand and push the tool forward and slightly upward. Then fit the hook of the tool into the eye of the buckle.
  4.  



Click image to see an enlarged view

Fig. Fig. 29: ... wrap it around the boot and insert it through the buckle once again, then fold the strap back slightly to hold its position



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Fig. Fig. 30: Position the tightening tool 1/2 in. (13mm) above the buckle (with the strap in the narrow slot of the tool), ...

  1. Tighten the strip by closing the tool handles. Rotate the tool (handles) downward while slowly releasing the pressure on the tool handles. Allow the tool (handles) to open progressively. Then open the tool entirely and remove it sideways.
  2.  
  3. If the strip is not tight enough, engage the tool a second or even a third time, always about 1 / 2 (13mm) from the buckle. When tightening always be careful to see that the strap slides in a straight line and without resistance in the buckle. An effective grip will be obtained only by following the above instructions.
  4.  



Click image to see an enlarged view

Fig. Fig. 31: ... push the tool forward and insert the lower tang into the buckle notch, then ...



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Fig. Fig. 32: ... tighten the strap by squeezing the tool handles together



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Fig. Fig. 33: Once the strap is tight enough, cut the strap off about 1/8 in. (3mm) from the buckle


WARNING
Never fold the strap back or bring the tool down while tightening, as this action will break the strap.

  1. When the strap is finally tight enough, remove the tool sideways and cut the strap off 1 / 8 in. (3mm) so that it does not overlap the edge of the buckle. Complete the installation by folding the strip back neatly.
  2.  

INSTALLATION-PLASTIC BOOT

See Figures 34 and 35

Click image to see an enlarged view

Fig. Fig. 34: The lip of the plastic boot should be settled in the third groove and the clamp installed over the second groove as shown

  1. Slide the small clamp onto the shaft.
  2.  
  3. Position the small end of the boot over the interconnecting shaft with the clip of the boot in the third groove, toward the center of the interconnecting shaft.
  4.  
  5. Position the clamp evenly over the boot. Place the clamp installation tool (C-4975 or the equivalent) over the bridge of the clamp and tighten the nut until the jaws of the tool are closed completely, face-to-face.
  6.  



Click image to see an enlarged view

Fig. Fig. 35: This special tool (or the equivalent) will be needed to tighten the clamps-the plastic boots require a much higher clamping force, so rubber boot clamps cannot be used

  1. After attaching the boot to the shaft, install the CV-joint following the procedure earlier in this section.
  2.  
  3. Position the large end of the boot on the housing and install the clamp by crimping the bridge of the clamp with the crimping tool (Special tool C-4975 or equivalent).
  4.  


WARNING
Use only the clamps provided in the boot package for this application, otherwise damage to the boot or CV-joint may occur.

 
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