Neon, 2000 - 2005

Rzeppa (Outer) Joint

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  1. Remove or disassemble the following:
    WARNING
    If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable.



    Halfshaft and place it in a soft-jawed vise
     
    Rzeppa joint boot clamps and slide the boot down the shaft
     
    Rzeppa joint housing, by sharply hitting it with a soft-faced hammer to drive it off the shaft
     
    Circlip from the shaft
     
    Boot by sliding it off the shaft
     



    Click image to see an enlarged view

    Fig. Aligning the cross splines with the shaft splines-Rzeppa joint



    Click image to see an enlarged view

    Fig. Driving the Rzeppa joint onto the shaft

  2.  

To assemble:

  1. Install or assemble the following:

    New small boot clamp and slide it onto the shaft
     
    Boot and slide it onto the shaft
     
    Circlip, if removed
     

  2.  
  3. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove.

    Halfshaft hub nut onto the Rzeppa joint threaded shaft so it is flush with the end
     
    Rzeppa joint, align the shaft splines and tap it onto the shaft with a soft-faced hammer so it locks on the circlip
     

  4.  
  5. Distribute 1 / 2 of the grease in the service package inside the Rzeppa joint housing and the other 1 / 2 inside the boot.
  6.  
  7. Install the new small boot clamp and position it evenly on the sealing boot
  8.  
  9. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
    WARNING
    The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand.

  10.  
  11. Position the boot onto the Rzeppa housing retaining groove and install the retaining clamp evenly on the boot.
  12.  
  13. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (fa