Durango, 2001-2005

CV-Joints

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Overhaul



Inner CV-Joint & Boot
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Axle halfshaft from the vehicle
     
    Inner tripod joint boot clamps
     
    Tripod joint housing
     
    Snapring
     
    Circlip
     
    Tripod joint
     

  4.  

To install:


NOTE
Use new snaprings, clips, and boot clamps for assembly.

  1. Install or connect the following:

    Tripod joint
     
    Circlip
     
    Snapring
     
    Tripod joint housing
     

  2.  
  3. Fill the tripod joint housing and boot with grease and tighten the boot clamps.
  4.  
  5. Install the axle halfshaft.

    Click image to see an enlarged view

    Fig. Boot clamp location

    Boot clamp location

    Click image to see an enlarged view

    Fig. Removing the snapring

    Removing the snapring

    Click image to see an enlarged view

    Fig. CV joint housing

    CV joint housing

    Click image to see an enlarged view

    Fig. Tripod joint

    Tripod joint

    Click image to see an enlarged view

    Fig. Housing bushing

    Housing bushing

    Click image to see an enlarged view

    Fig. Inner CV joint boot

    Inner CV joint boot
  6.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Clamp the shaft in a vise with soft jaws and support the CV joint.
  4.  
  5. Remove the clamps with a cut-off wheel or grinder.
    WARNING
    Do not damage the CV housing or half shaft with the cut-off wheel or grinder.

  6.  
  7. Remove the housing from the half shaft and slide the boot down shaft.
  8.  
  9. Remove the housing bushing from the housing.
  10.  
  11. Remove the tripod snapring.
  12.  
  13. Remove the tripod and boot from the halfshaft.
  14.  
  15. Clean and inspect the CV components for excessive wear and damage. Replace the tripod as a unit only if necessary.
  16.  

To install:

  1. Slide a new boot down the halfshaft.
  2.  
  3. Install the tripod and tripod snapring on the halfshaft.
  4.  
  5. Pack the grease supplied with the joint/boot into the housing and boot.
  6.  
  7. Coat the tripod with the supplied grease.
  8.  
  9. Install new bushing onto the housing.
  10.  
  11. Insert the tripod and shaft in the housing.
  12.  
  13. Position the boot on the joint in its original position.
    NOTE
    Verify the boot is not twisted and remove any excess air.

  14.  
  15. Secure both boot clamps with Clamp Installer C-4975A, or equivalent. Place the tool on the clamp bridge and tighten the tool until the jaws of the tool are closed.
  16.  

Outer CV-Joint
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Axle halfshaft from the vehicle
     
    CV-joint boot and clamps
     
    Snapring
     
    CV-joint
     

  4.  

To install:

  1. Install or connect the following:

    CV-joint
     
    Snapring
     
    CV-joint boot and clamps
     

  2.  
  3. Fill the joint housing and boot with grease and tighten the boot clamps.
  4.  
  5. Install the axle halfshaft.
  6.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Place shaft in vise with soft jaws and support CV-joint.
    CAUTION
    Do not damage CV-joint housing or halfshaft.

  4.  
  5. Remove clamps with a cut-off wheel or grinder.
  6.  
  7. Slide the boot down the shaft.
  8.  
  9. Remove lubricant to expose the CV-joint snapring.

    Click image to see an enlarged view

    Fig. Removing the snapring (1) from the shaft (2) with snapring pliers (3)

    Removing the snapring (1) from the shaft (2) with snapring pliers (3)
  10.  
  11. Spread snapring and slide the joint off the shaft.
  12.  
  13. Slide boot off the shaft and discard old boot.
  14.  
  15. Mark alignment marks on the inner race/hub, bearing cage and housing with dabs of paint.

    Click image to see an enlarged view

    Fig. Make alignment marks (1) on the inner race/hub (2) and cage (3)

    Make alignment marks (1) on the inner race/hub (2) and cage (3)
  16.  
  17. Clamp CV-joint in a vertical position in a soft jawed vise.
  18.  
  19. Press down one side of the bearing cage to gain access to the ball at the opposite side.
    NOTE
    If joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift.

  20.  
  21. Remove ball from the bearing cage.
  22.  
  23. Repeat step above until all six balls are removed from the bearing cage.

    Click image to see an enlarged view

    Fig. Removing the balls from the bearing cage

    Removing the balls from the bearing cage

    Click image to see an enlarged view

    Fig. Removing the cage and inner race from the housing

    Removing the cage and inner race from the housing

    Click image to see an enlarged view

    Fig. Removing the inner race/hub from the cage

    Removing the inner race/hub from the cage
  24.  
  25. Lift cage and inner race upward and out from the housing.
  26.  
  27. Turn inner race 90° in the cage and rotate the inner race/hub out of the cage.
  28.  

To Install:

Click image to see an enlarged view

Fig. Assembling the inner race cage and housing

Assembling the inner race cage and housing

  1. Apply a light coat of grease to the CV-joint components before assembling them.
  2.  
  3. Align inner race, cage and housing according to the alignment reference marks.
  4.  
  5. Insert inner race into the cage and rotate race into the cage.
  6.  
  7. Rotate inner race/hub in the cage.
  8.  
  9. Insert cage into the housing.
  10.  
  11. Rotate cage 90° into the housing.
  12.  
  13. Apply lubricant included with replacement boot/joint to the ball races. Spread lubricant equally among all the races.
  14.  
  15. Tilt inner race/hub and cage and install the balls.
  16.  
  17. Place new clamps onto new boot and slide boot onto the shaft to its original position.
  18.  
  19. Apply the rest of lubricant to the CV-joint and boot.
  20.  
  21. Push the joint onto the shaft until the snapring seats in the groove. Pull on the joint to verify the span ring has engaged.
  22.  
  23. Position boot on the joint in its original position. Ensure boot is not twisted and remove any excess air.
  24.  
  25. Secure both boot clamps with Clamp Installer C-4975A, or equivalent. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed.
  26.  

 
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