GrandCaravan 2008

Halfshafts

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CV-Boots Inspection



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Check the driveshaft boots for damage and deterioration:

    Raise the front of the vehicle
     
    Rotate the axle and inspect for cracked or ripped CV boot material on the inner and outer CV-joints. Repeat this step on both sides of the vehicle.
     
    Inspect for excessive grease deposits on or around the CV boot
     

  4.  
  5. Replace the boot if it is damaged or deteriorated.
  6.  

Removal & Installation



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly from the vehicle.
  6.  
  7. With the vehicle brakes applied to keep the hub from turning, loosen the halfshaft nut.
  8.  
  9. Remove the nut from the halfshaft.
  10.  
  11. Remove the front brake rotor from the hub and bearing assembly. Refer to Front Disc Brakes, Rotor, removal & installation.
  12.  
  13. Remove the steering knuckle-to-strut attachment bolts (2) from the steering knuckle (3).

    Click image to see an enlarged view

    Fig. Install the hub and bearing onto the halfshaft stub shaft and into the knuckle

  14.  
  15. Pull the steering knuckle from the strut clevis bracket.
    WARNING
    Never grasp the halfshaft assembly by the inner or outer boots as doing so may cause damage to the boot.


    WARNING
    Care must be taken not to separate the inner CV-joint during this operation. Do not allow the halfshaft to hang by the inner CV-joint after removing the outer CV-joint from the hub/bearing assembly in the steering knuckle, the end of halfshaft must be supported.

  16.  
  17. Pull the steering knuckle assembly down and away from the outer CV-joint of the halfshaft assembly while pulling the joint out of the hub bearing.
  18.  
  19. Support the outer end of the halfshaft assembly. Insert a pry bar between the inner tripod joint and the transaxle case. Pry against the inner tripod joint until the tripod joint retaining snap-ring is disengaged from the transaxle side gear.
  20.  
  21. Pull the steering knuckle from the strut clevis bracket.
  22.  
  23. Pull the steering knuckle assembly down and away from the outer CV-joint of the halfshaft assembly while pulling the joint out of the intermediate shaft (if equipped) or the transaxle.
  24.  
  25. Remove the bolts at the heat shield and remove the heat shield, if equipped.
  26.  
  27. Remove the 3 bolts (1) holding the mid-shaft bearing (2) to the block.
  28.  
  29. Remove the intermediate shaft.

    Click image to see an enlarged view

    Fig. Remove the 3 bolts (1) holding the mid-shaft bearing (2) to the block

  30.  

To install:

  1. Install the intermediate shaft into the transaxle.
  2.  
  3. Install the 3 bolts (1) holding the mid-shaft bearing (2) to the block and tighten to 39 ft. lbs. (54 Nm).
  4.  
  5. Install the heat shield and bolts, tighten to 40 inch lbs. (6 Nm), if equipped.
    NOTE
    A rubber coated washer on the outer CV-joint stem is used and should be in place during assembly.

  6.  
  7. Thoroughly clean the splines and the oil seal sealing surface on the tripod joint. Lightly lubricate the oil seal sealing surface on the tripod joint with fresh clean transaxle lubricant and install the rubber coated washer.
  8.  
  9. Holding the halfshaft assembly by the tripod joint and the interconnecting shaft, install the tripod joint into the transaxle side gear, as far as possible, by hand. Be sure to engage the splines prior to applying force.
  10.  
  11. Forcefully push the tripod joint onto the intermediate shaft, until the snap-ring is engaged.
  12.  
  13. Clean all debris and moisture out of the steering knuckle, in the area where the outer CV-joint will be installed into the steering knuckle.
  14.  
  15. Ensure that the front of outer CV-joint, which fits against the face of the hub and bearing, is free of debris and moisture before installing the outer CV-joint into the hub and bearing assembly.
  16.  
  17. Slide the halfshaft back into the front hub and bearing assembly.
    NOTE
    The steering knuckle-to-strut assembly attaching bolts are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle.


    NOTE
    If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket.

  18.  
  19. Install steering knuckle in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both bolts to a torque of 65 ft. lbs. (88 Nm), plus an additional 1 / 4 turn.
  20.  
  21. Install the braking disc on the hub and bearing assembly.
  22.  
  23. Install the disc brake caliper assembly on the steering knuckle. The caliper is installed by first sliding the bottom of the caliper assembly under the abutment on the steering knuckle, and then, rotating the top of the caliper against the top abutment.
  24.  
  25. Install the disc brake caliper adapter to the steering knuckle attaching bolts. Tighten the disc brake caliper adapter attaching bolts to 125 ft. lbs. (169 Nm).
    NOTE
    The seal boot must not be dimpled, stretched, or out of shape in any way. If the seal boot is NOT shaped correctly, equalize the pressure in the seal and shape it by hand.

  26.  
  27. Clean all foreign matter from the threads of the outer CV-joint. Install the halfshaft to the hub/bearing assembly nut on the halfshaft and securely tighten the nut.
  28.  
  29. Install the front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in the proper sequence until all nuts are torqued to 1 / 2 the required specification. Then, repeat the tightening sequence to the full specified torque of 100 ft. lbs. (135 Nm).
  30.  
  31. Lower the vehicle.
  32.  
  33. With the vehicle brakes applied to keep the hub from turning, tighten the hub nut to a torque of 118 ft. lbs. (160 Nm).
  34.  
  35. Check for the correct fluid level in the transaxle assembly and add as necessary.
  36.  

 
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