PT Cruiser 2006-2007

Halfshafts

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CV-Joints



Inspection
  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 vehicle.
     
    Inspect for excessive grease deposits on or around the CV boot
     

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

Overhaul
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.  

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 CV-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.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Place the transaxle in the PARK position, for automatic, and neutral for manual.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Be careful when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get damaged.


    WARNING
    Be careful when separating the inner CV-joint during this operation. Do not let the driveshaft hang by the inner CV-joint, the driveshaft must be supported.


    NOTE
    Inner Tri-Pot joint removal is easier by applying outward pressure on the joint while hitting the punch with a hammer.



    The negative battery cable
     
    The front wheel
     
    The cotter pin, locknut and spring washer from the end of the outer Constant Velocity (CV) joint stub axle
     
    The driveshaft to hub and bearing nut
     
    The front wheel speed sensor, if equipped
     
    The steering knuckle from the ball joint
     
    The driveshaft from the steering knuckle and support the outer end of the driveshaft
     

  6.  
  7. Remove the inner Tri-Pot joints from the transaxle side gears using a punch to dislodge the inner Tri-Pot joint retaining ring from the transaxle side gear.
  8.  
  9. If removing the right side inner Tri-Pot joint, position the punch against the inner Tri-Pot joint. Hit the punch sharply with a hammer to dislodge the right inner joint from the side gear.
  10.  
  11. If removing the left side inner Tri-Pot joint, position the punch in the groove of the inner Tri-Pot joint. Hit the punch sharply with a hammer to dislodge the left inner Tri-Pot joint from the side gear.
  12.  
  13. Hold the inner Tri-Pot joint and interconnecting shaft of the driveshaft assembly. Remove the inner Tri-Pot joint from the transaxle by pulling it straight out of the transaxle side gear and transaxle oil seal. When removing the Tri-Pot joint, do not let the spline or snapring drag across the sealing lip of the transaxle-to-Tri-Pot joint oil seal.
    WARNING
    The driveshaft, when installed, acts as a bolt which secures the front hub and bearing assembly. If the vehicle is to be supported or moved on its wheels with a driveshaft removed, install a proper-sized bolt and nut through the front hub. Tighten the bolt and nut to 135 ft. lbs. (183 Nm). This will ensure that the hub bearing cannot loosen.



    Click image to see an enlarged view

    Fig. Remove the Tri-Pot joint from the transaxle

  14.  

To install:

  1. Thoroughly clean the spline and oil seal sealing surface on the Tri-Pot joint. Lightly lubricate the oil seal sealing surface on the Tri-Pot joint with fresh, clean transmission fluid.
  2.  
  3. Holding the driveshaft assembly by the Tri-Pot joint and interconnecting shaft, install the Tri-Pot joint into the transaxle side gear as far as possible by hand
  4.  
  5. Align the Tri-Pot joint with the transaxle side gears, grasp the driveshaft interconnecting shaft and push the Tri-Pot joint into the transaxle side gear until fully seated. Be sure the snapring is fully engaged with the side gear by trying to remove the Tri-Pot joint from the transaxle by hand. If the snapring is fully seated with the side gear, the Tri-Pot joint will not be removable by hand.
  6.  
  7. Install or connect the following:

    The driveshaft back into the front hub
     
    The steering knuckle into the ball joint stud
     
    The new steering knuckle-to-ball joint stud bolt and nut. Torque the nut and bolt to 70 ft. lbs. (95 Nm)
     
    The washer and hub nut to the stub axle and torque the nut to 180 ft. lbs. (244 Nm)
     
    The spring washer, locknut and cotter pin
     
    The VSS, if equipped
     
    The front wheel
     
    The negative battery cable
     

  8.  
  9. Check the transaxle fluid and adjust if needed.
  10.  

 
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