PT Cruiser, 2001 - 2005

CV-Joints Overhaul

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Outer Joint



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the halfshaft.
  4.  
  5. Remove the clamps from the CV-joint boot and discard.
  6.  
  7. Remove the boot from the CV-joint housing and slide it down the interconnecting shaft.
  8.  
  9. Remove the outer CV-joint from the interconnecting shaft by sharply hitting it with a soft-faced hammer to drive it off the shaft.
  10.  
  11. Remove the circlip from the shaft.
  12.  
  13. Remove the CV-joint by sliding it off the shaft.
    WARNING
    If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable.



    Click image to see an enlarged view

    Fig. Remove the outer C/V joint from the interconnecting shaft

  14.  

To install:

  1. Install a new small boot clamp and slide it onto the shaft.
  2.  
  3. Install the boot and slide it onto the shaft.
  4.  
  5. Install the circlip.
  6.  
  7. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove.
  8.  
  9. Install the halfshaft hub nut onto the joint threaded shaft so it is flush with the end.
  10.  
  11. Align the shaft splines and tap it onto the shaft with a soft-faced hammer so it locks on the circlip.
  12.  
  13. Distribute 1 / 2 of the grease in the service package inside the joint housing and the other 1 / 2 inside the boot.
  14.  
  15. Install a new small boot clamp and position it evenly on the sealing boot.
    CAUTION
    Clamp the boot to the shaft 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.

  16.  
  17. Position the boot onto the retaining groove and install the retaining clamp evenly on the boot.
  18.  
  19. Clamp the boot to the outer CV-joint housing 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).
  20.  
  21. Install the halfshaft.
  22.  

Tri-Pot (Inner) Joint



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Remove the halfshaft.
  6.  
  7. Remove the tri-pot joint boot clamps and slide the boot down the shaft.
    WARNING
    When removing the spider joint, hold the rollers in place on the trunnions to keep the rollers and needle bearings in place.

  8.  
  9. Slide the interconnecting shaft and spider assembly from the tri-pot housing.
  10.  
  11. Remove the snapring from the shaft.
  12.  
  13. Remove the spider assembly.
    NOTE
    If necessary, tap the spider assembly from the shaft with a brass drift.


    WARNING
    When removing the spider assembly, do not hit the outer bearings.

  14.  
  15. Remove the boot by sliding it off the shaft.
    WARNING
    If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable.

  16.  

To install:

Click image to see an enlarged view

Fig. Install the Tri-Pot housing on to the spider assembly


WARNING
The Tri-pot sealing boots are made of 2 different types of material, silicon rubber (high temperature) which is soft and pliable or hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot made of the correct material.

  1. Install a new small boot clamp and slide it on the shaft.
  2.  
  3. Install the boot and slide it on the shaft.
  4.  
  5. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove.
  6.  
  7. Install the spider assembly, face the chamfered side toward the shaft.
  8.  
  9. Install the snapring making sure it is fully seated in the groove.
  10.  
  11. Install the spider/shaft assembly into the tri-pot housing.
  12.  
  13. Install a new inner boot clamp and position it evenly on the sealing boot.
  14.  
  15. Using a trim stick, adjust the boot length to 115mm (hytrel plastic) or 115mm (silicone rubber).
  16.  
  17. If installing a high profile boot clamp, perform the following procedure:
    1. 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.

    2.  
    3. Position the boot onto the tri-pot housing retaining groove and install the retaining clamp evenly on the boot.
    4.  
    5. 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).
    6.  

  18.  
  19. If installing a low profile latching type boot clamp, position Snap-On® Clamp Locking Tool YA3050 prongs in the clamp holes and squeeze the tool until the upper clamp band is latched behind the 2 tabs on the lower clamp band.
  20.  
  21. Install the halfshaft.
  22.  
  23. Connect the negative battery cable.
  24.  

 
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