Crossfire 2006-2008

Halfshafts

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CV-Joints



Overhaul
Inner Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Axle halfshaft from the vehicle
     
    CV joint boot clamps
     

  4.  
  5. Clamp the halfshaft in a vise.
  6.  
  7. Pry the joint cover from the bearing retainer.
  8.  
  9. Remove the boot from the inner seal.
  10.  
  11. Pry the inner seal from the bearing retainer.
  12.  
  13. Slide the boot, inner seal and bearing retainer off the halfshaft.
  14.  
  15. Remove the circlip from the axle shaft.
  16.  
  17. Using a press, remove the inner joint bearing from the halfshaft.

    Click image to see an enlarged view

    Fig. Removing the boot from inner seal

  18.  

To install:


NOTE
Use new circlips and boot clamps for assembly.

  1. Install or connect the following:

    Inner boot
     
    Inner joint bearing
     
    Inner seal
     
    Circlip
     

  2.  
  3. Fill the bearing housing with grease.
  4.  
  5. Apply a bead of sealant to the outer sealing surface of the joint ring.
  6.  
  7. Using a mallet, tap on a NEW joint cover.
  8.  
  9. Install the boot into the sealing groove of the inner seal.
  10.  
  11. Install the retaining clamps and crimp in place.
  12.  
  13. Install the axle halfshaft.
  14.  

Outer Joint
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Axle halfshaft from the vehicle
     
    Inner CV-joint boot and clamps
     
    Outer CV-joint and boot
     

  4.  

To install:

  1. Pack the outer CV-joint with grease supplied in repair kit.
  2.  
  3. Install or connect the following:

    CV-joint into inner seal
     

  4.  
  5. Crimp the retaining boot clamps.
  6.  
  7. Install the axle halfshaft.

    Click image to see an enlarged view

    Fig. CV Joint boot clamps

  8.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the rear wheels.
  6.  
  7. Remove the rear knuckle.
    NOTE
    The axle halfshafts are seated in the differential side gears using expandable snap rings. It is necessary to forcefully pry the halfshaft out of the differential.

  8.  
  9. Insert a pry bar between the differential housing and the halfshaft.
  10.  
  11. Pry against differential housing until the halfshaft retaining snap ring is disengaged from the differential side gear.
    WARNING
    When removing the halfshaft assembly do not allow the snap ring to drag across the sealing lip of the differential oil seal.

  12.  
  13. Carefully pull the halfshaft out of the differential housing and remove the halfshaft from the vehicle.

    Click image to see an enlarged view

    Fig. Overview of rear knuckle (1) removal



    Click image to see an enlarged view

    Fig. Removing halfshaft (1) from differential housing

  14.  

To install:

  1. Thoroughly clean the spline and oil sealing surface of the halfshaft.
  2.  
  3. Lightly lubricate the oil seal sealing surface of the halfshaft with clean lubricant.
  4.  
  5. Insert the halfshaft outer end through the wheel hub.
  6.  
  7. Install the halfshaft into the differential side gear as far as possible by hand.
  8.  
  9. Forcefully push the halfshaft into the differential side gear until the snap ring is engaged with the differential side gear.
    NOTE
    Grasp the halfshaft and test the snap ring and ensure it is fully engaged with the side gear.

  10.  
  11. Install the rear knuckle.
  12.  
  13. Use a new halfshaft outer retaining nut and tighten to 164 ft. lbs. (220 Nm).
  14.  
  15. Install the rear wheels.
  16.  

 
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