Chrysler Full-Size Trucks 1997-2000 Repair Guide

CV Joints

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CV JOINT BOOTS



REMOVAL & INSTALLATION
  1. Remove the axle driveshaft.
  2.  
  3. Remove the outer CV joint.
  4.  
  5. Remove the outer CV joint small clamp. Remove boot.
  6.  
  7. Remove the inner CV joint boot clamps and remove boot.
  8.  
  9. The lubricant amounts included with replacement boots are different for inner and outer units. Apply only the included amount on each joint.
  10.  
  11. Clean the CV joints and shaft of old grease and foreign matter.
  12.  
  13. Slide the inner CV joint boot up the shaft and insert the lip located within the small diameter end of the boot into the shaft groove.
  14.  
  15. Retain the small diameter of the boot on the shaft with a ladder-type clamp in the boot groove. Verify that the boot and lip are properly positioned on the intermediate shaft. Position the clamp locating tabs in the slots and tighten the clamp.
  16.  
  17. Squeeze the clamp bridge. Take care that you don't cut through the clamp bridge or damage the boot.
  18.  
  19. Position the large diameter end of the boot on the CV joint housing.
  20.  
  21. After the inner joint boot small clamp is installed, the inboard hub must be set to a service build length.
  22.  
  23. Compress the inner hub down the connector shaft.
  24.  
  25. Use a small blunt drift between the large end and the boot seal to relive the pressure.
  26.  
  27. The distance from the edge of the lip to the edge of the flange should be 7.5 in. (190mm) on 1997 models, and 7.1 in. (181mm) on other models. This will eliminate excess air that can cause a ballooning effect and possibly damage the boot.
  28.  
  29. Verify correct (untwisted) boot positioning.
  30.  
  31. Install the large ladder clamp and secure it.
  32.  
  33. Slide the outer CV joint boot small clamp onto the shaft.
  34.  
  35. Slide the outer CV joint boot onto the shaft and into position.
  36.  
  37. Install the small clamp to boot.
  38.  
  39. Install the large boot clamp over the outer CV joint.
  40.  
  41. Install the outer CV joint to the shaft.
  42.  
  43. Install the large boot clamp to boot and CV joint.
  44.  
  45. Install the CV driveshaft.
  46.  



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Fig. Boot retaining clamp locations



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Fig. Compressing the clamp bridge

DISASSEMBLY & ASSEMBLY



Inner CV Joint
  1. Remove the axle driveshaft.
  2.  
  3. Place the inner CV joint housing in a vise.
  4.  
  5. Remove the inner boot retaining clamps. Pull the inner boot back onto the interconnecting shaft. Discard the retaining clamps.
  6.  
  7. Pull the tripod and shaft straight out from the inner CV joint housing.
  8.  
  9. Remove the snap retaining ring from the groove behind the tripod. Slide the tripod toward the center of the shaft. Remove the C-clip on the outer end of the shaft.
  10.  
  11. Remove the tripod from the shaft. Replace the boot, if necessary.
  12.  
  13. Remove old lubricant.
  14.  
  15. Inspect the needle bearing raceways in the housing and tripod components for wear and damage. Replace the tripod as a unit only if necessary.
  16.  
  17. Inspect the balls for pitting, cracks, scoring and wear. A dull surface is normal.
  18.  
  19. Polished contact surface areas on the raceways and on the bearing surfaces are normal. If the joints are noisy or cause vibration, they should be replaced.
  20.  
  21. To assemble, slide the boot down far enough for access.
  22.  
  23. Install the snap ring past the ring groove (towards the center of the shaft). Slide the tripod onto the end of the interconnecting shaft. Be sure the chamfered end of the tripod is adjacent to the C-clip retaining ring groove.
  24.  
  25. Install the C-clip in the groove. Slide the tripod out against the clip. Install the snap ring in the inner groove. Be sure they are seated.
  26.  
  27. Apply the required quantity of lubricant to the housing and boot. Coat the interior of the joint housing and the tripod.
  28.  
  29. Insert and seat the tripod and shaft in the housing.
  30.  
  31. Position the large diameter end of the inner CV joint boot over the edge of the housing. Insert the lip of the boot into the locating groove at the edge of the housing.
  32.  
  33. Install the CV joint boots as outlined in that section.
  34.  



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Fig. Driveshaft CV joint components



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Fig. Removing the snap ring-inner CV joint



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Fig. Removing the C-clip-inner CV joint

Outer CV Joint

If the outer CV joint is excessively worn, replace the entire CV joint and boot.

  1. Remove the retaining clamps from the outer CV joint and discard. Slide the boot off the outer joint and down the shaft.
  2.  
  3. Remove the lubricant to expose the outer CV joint components.
  4.  
  5. Clamp the shaft in a vise with soft jaws and support the outer CV joint.
  6.  
  7. Remove the snap ring from the groove.
  8.  
  9. Slide the outer CV joint from the shaft.
  10.  
  11. Remove the slinger, if damaged, from the outer CV joint with a brass drift.
  12.  
  13. Clean the old lubricant.
  14.  
  15. Matchmark the bearing hub, bearing cage and housing.
  16.  
  17. Clamp the outer CV joint in a vertical position. Place the stub shaft in a soft-faced vise.
  18.  
  19. Press down on one side of the bearing cage/hub to tilt the cage. This will provide access to a ball at the opposite side. If the joint is tight, use a hammer and brass drift to loosen the hub. Do NOT contact the bearing cage with the drift.
  20.  
  21. Remove the ball from the bearing cage. If necessary, a small pry bar cab be used.
  22.  
  23. Repeat these steps until all balls are removed.
  24.  
  25. Tilt the bearing cage to a vertical position. Remove the cage from the housing. Pull the cage upwards and away from the housing.
  26.  
  27. Turn the bearing hub 90º from the bearing cage. Align one pair of the hub lands with the cage windows. Raise and insert one of the lands with the cage windows. Raise and insert one of the lands into the adjacent cage window. Remove the bearing hub by rolling it out of the cage.
  28.  
  29. Inspect the balls for pitting, cracks, scoring and wear. A dull surface is normal.
  30.  
  31. Polished contact surface areas on the raceways and on the bearing surfaces are normal. If the joints are noisy or cause vibration, they should be replaced.
  32.  
  33. To assemble, first apply a light coat of oil to all the outer components.
  34.  
  35. Align the bearing hub, cage and housing with the matchmarks made during disassembly.
  36.  
  37. Insert one of the bearing hub lands into a bearing cage window. Roll the hub into thew cage. Rotate the bearing hub 90º to compete the installation.
  38.  
  39. Insert the bearing cage/hub into the housing. Rotate the cage/hub 90º to complete the installation.
  40.  
  41. Apply lubricant to the ball raceways. Spread equally between all raceways.
  42.  
  43. Tilt the bearing hub and cage and install the balls in the raceways.
  44.  
  45. Apply a small amount of lubricant to the inner diameter of the slinger. Drive it squarely on.
  46.  
  47. Position the small diameter end of the replacement boot on the interconnecting shaft. Retain the boot with a replacement clamp.
  48.  
  49. Lubricate the outer CV joint and boot.
  50.  
  51. Align the shaft splines to the outer CV joint splines. Push the outer CV joint until the snap ring seats in the groove.
  52.  
  53. Ensure that the snap ring is properly seated in the housing. Pull the outer CV joint from the interconnecting shaft to test.
  54.  
  55. Install the boot as outlined previously.
  56.  



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Fig. Outer CV joint components



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Fig. Matchmark the bearing hub, cage and housing before disassembly



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Fig. Removing a ball from the assembly. Use a small pry bar, if necessary



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Fig. Bearing cage and hub removal method



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Fig. Bearing hub removal



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Fig. Hub installation technique



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Fig. Assembled bearing cage and hub



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Fig. Bearing cage and hub installation



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Fig. Bearing cage and hub installed in housing

 
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