Chrysler Full-Size Trucks 1989-1996 Repair Guide

Rear Driveshaft and U-Joints

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REMOVAL & INSTALLATION



One-Piece Driveshaft

See Figures 1, 2, 3, 4, 5, 6 and 7

  1. Raise the vehicle and support safely.
  2.  
  3. Matchmark the driveshaft and the rear axle drive pinion gear shaft yoke.
  4.  
  5. Remove the rear U-joint attaching bolts and both strap clamps from the rear axle drive gear shaft yoke.
  6.  
  7. Fluid may run from the rear of the extension housing or transfer case when the shaft is removed, so position a suitable drain pan under the area.
  8.  
  9. Remove the driveshaft from the transmission or transfer case.
  10.  
  11. The installation is the reversal of the removal procedure. Tighten 1 / 4 - 28 clamp bolts to 14 ft. lbs. (19 Nm) and 5 / 16 - 24 to 25 ft. lbs. (34 Nm).
  12.  

Two-Piece Driveshaft

This driveshaft has a universal joint at either end, with a third universal joint and a support bearing at the center.

  1. Matchmark the shaft and the rear axle pinion hub yoke. Matchmark the center bearing spline and slip yoke.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Alignment points for the 2-piece (and 1-piece) driveshaft

Do not allow the driveshaft to hang down the during removal. Suspend it from the frame. Raise the rear of the truck to prevent loss of transmission fluid.



Click image to see an enlarged view

Fig. Fig. 2: Matchmark the link yoke as shown for correct alignment upon reinstallation

  1. Remove both rear U-joint roller and bushing assembly clamps from the rear axle pinion yoke. Do not disturb the retaining strap used to hold the bushing assemblies on the U-joint cross.
  2.  
  3. Slide the rear half of the shaft off the front shaft splines at the center bearing. Remove the rear half.
  4.  
  5. At the transmission end of the front half, remove the bushing retaining bolts and clamps, after matchmarking. If there is a driveshaft brake, there will be flange nuts.
  6.  
  7. Unbolt the center bearing mounting nuts and bolts and remove the front half of the shaft.
  8.  

To install:
  1. Align the matchmarks at the transmission and start all the bolts and nuts at the front U-joint and the center support bearing.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the halfshafts, center bearing and mounting bracket

  1. Tighten 1 / 4 in. clamp bolts to 170 inch lbs. (19 Nm) and 5 / 16 in. bolts to 300 inch lbs. (34 Nm). Tighten driveshaft brake flange nuts to 35 ft. lbs. (47 Nm). Leave the center bearing bolts just snug.
  2.  
  3. Align the rear U-joint matchmarks and install the bushing clamps and bolts. Tighten the bolts to the torque given in Step 7. Grease the joints and splines.
  4.  
  5. Jack up the rear wheels and let the engine drive the shaft. The center support bearing will align itself.
  6.  
  7. Tighten the center bearing bolts to 50 ft. lbs. (68 Nm).
  8.  

U-JOINT REPLACEMENT



Single Cardan Universal Joint
  1. Remove the driveshaft and slip yoke, if equipped from the vehicle.
  2.  

Do not clamp the driveshaft tube in a vise. Clamp only the forged portion of the welded yoke or the slip yoke in a vise. Do not overtighten the vise jaws.

Click image to see an enlarged view

Fig. Fig. 4: Exploded view of a single cardan-type U-joint assembly at the fixed yoke

  1. Clamp the yoke in a vise and remove the bearing cap retainers.
  2.  
  3. Place a socket which has an inside diameter larger than the outside diameter of the bearing cap, against the yoke around the perimeter of the first cap to be removed. Place a socket which is slightly smaller than the cap, on the cap, opposite the cap to be removed. Then position the yoke in a vise.
  4.  
  5. Compress the jaws until the smaller socket has driven the other cap into the larger socket.
  6.  
  7. Release the jaws and remove the cap that is partially out of the yoke.
  8.  
  9. Repeat the procedure for the remaining cap(s).
  10.  

To install:
  1. Clean and remove and rust from the yoke bores and lubricate lightly with suitable lithium based grease.
  2.  
  3. Position the spider cylinders in the yoke bores. Insert the seals into the yoke bore and against the spider cylinders. Tap the bearing caps into the yoke bores far enough to keep the spider in place.
  4.  
  5. Place the socket that is slightly smaller than the cap against the first cap and position the assembly in a vise.
  6.  
  7. Compress the jaws to force the bearing caps into the yoke bores far enough so the retainer grooves are visible.
  8.  
  9. Repeat the procedure for the remaining caps if necessary.
  10.  
  11. Install the retaining clips.
  12.  
  13. Install the driveshaft assembly to the vehicle.
  14.  

Double Cardan Constant Velocity Joint

  1. Remove the front driveshaft from the vehicle.
  2.  
  3. Matchmark the yokes before disassembling so they will be installed in their original locations to retain driveshaft balance.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of a double cardan-type CV-joint

  1. To expedite removal, remove the bearing caps in the sequence indicated.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Removal sequence for the bearing cap-double cardan-type CV-joint

  1. Support the driveshaft horizontally and aligned with the base plate of the press. Shear the bearing cap plastic retaining ring and position the first link yoke rear arm over a 1 1 / 8 in. (29mm) socket. Place Spider Press Tool C-4365-1, or equivalent, on the bearing caps in the flange yoke arms. Force the bearing caps out of the yoke with a press.
  2.  
  3. If the bearing cap is not completely removed, insert a suitable spacer between the spider and bearing cap and complete the removal.
  4.  
  5. Rotate the driveshaft 180° and repeat the procedure.
  6.  
  7. Disengage the spider trunnions from the link yoke. Pull the flange yoke and the spider from the centering ball on the ball support tube yoke.
  8.  
  9. To remove the ball socket, separate the CV-joint between the link yoke and the flange yoke by forcing the spider trunnion bushing from the link yoke. Pull the flange yoke and the spider with the ball socket from the centering ball as an assembly.
  10.  
  11. Pry the seal from the ball socket and remove the washers, spring and 3 ball seats.
  12.  
  13. Remove the centering ball from the ball socket using Tool set C-4365, or equivalent.
  14.  



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the CV driveshaft components-Dakota models

To install:
  1. Install the centering ball in the socket using special tool C-4365-3, or equivalent. Force the ball into the socket until it is seated firmly against the shoulder at the base of the socket.
  2.  
  3. To install the spider, insert one bearing cap partially into on of the yoke bores and then rotate the yoke 180°. Insert the spider into the yoke bore and seat the spider trunnion in the bearing cap. Partially insert the opposite bearing cap in the remaining yoke bore.
  4.  
  5. Force the bearing caps inward while pivoting the spider back and forth to provided free movement of the trunnions in the bearing.
  6.  
  7. When the retainer grooves become visible, install the retainer.
  8.  
  9. Continue to force the caps inward until the opposite retainer can be installed in its groove.
  10.  
  11. Lubricate the centering ball and socket with the lubricant provided in the replacement kit.
  12.  
  13. Repeat the installation procedure with the remaining portion of the assembly.
  14.  

 
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