Pacifica, 2003-2005

Removal & Installation

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WARNING
The rear suspension and drivetrain design requires this procedure to be performed on a drive on hoist as the front and rear suspension must be compressed to the vehicle ride height.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Wheel cover cap
     
    Cotter pin, locknut and washer
     
    Exhaust system center hanger at the propeller shaft center bearing
     
    Exhaust system at the rear hanger and lower at least 10 inches (254mm) before securing with wire
     

  4.  
  5. Mark the propeller shaft and rear driveline module flanges for reference during installation.

    3 propeller shaft-to-driveline module bolts. Do not disconnect the shaft from the module as it will be disconnected upon lowering the module.
     

  6.  
  7. Support the driveline module with a transmission jack.
  8.  
  9. Using a suitable prytool, partially dislodge the halfshaft from the differential.
  10.  
  11. Install seal protector tool 9099 to protect the seal during disassembly.
  12.  
  13. Remove the 3 driveline-to-crossmember bolts.
  14.  
  15. Lower the driveline module enough to remove the shaft from the differential, making sure tool 9099 engages the seal.
  16.  
  17. Disconnect the propeller shaft from the differential and secure it to the exhaust system.
  18.  
  19. Remove the halfshaft from the bearing assembly.

    Click image to see an enlarged view

    Fig. support the driveline module using a transmission jack

    support the driveline module using a transmission jack

    Click image to see an enlarged view

    Fig. Use seal protector tool 9099 to protect against seal damage

    Use seal protector tool 9099 to protect against seal damage
  20.  

To install:

  1. Remove the halfshaft from the bearing assembly. Install the hub nut and washer and hand tighten.
  2.  
  3. Attach the shaft to the differential, using tool 9099.
  4.  
  5. Connect the propeller shaft to the module flange. Install but do not tighten the 3 bolts
  6.  
  7. Position the module and tighten the module-to-cradle bolts to 75 ft. lbs. (102 Nm).
  8.  
  9. Tighten the propeller shaft-to-module bolts to 40 ft. lbs. (54 Nm)
  10.  
  11. Tighten the halfshaft nut to 180 ft. lbs. (244 Nm).
  12.  
  13. Install or connect the following:

    Washer, nut and new cotter pin
     
    Wheel cover cap
     
    Negative battery cable
     

  14.  
  15. Check and adjust the differential fluid.
  16.  
  17. Road test the vehicle to check for noise or vibration.
  18.  

Front




WARNING
Allowing the CV-joint assemblies to dangle unsupported, or pulling or pushing the ends, can damage boots or CV-joints. Always support both ends of the halfshaft to prevent damage or disengagement of the Tri-pot joint.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Hub and bearing-to-stub axle cotter pin and retainer nut
     
    Front wheels
     
    Front caliper assembly from steering knuckle
     
    Front brake rotor from the hub
     
    Steering knuckle-to-strut bolts
     
    Steering knuckle from the strut bracket
     
    Knuckle down and away from the outer CV-joint while pulling the joint out of the bearing assembly

    Click image to see an enlarged view

    Fig. Exploded view of the front halfshaft and related components

    Exploded view of the front halfshaft and related components

    Click image to see an enlarged view

    Fig. Use a prybar to disengage the halfshaft from the transaxle

    Use a prybar to disengage the halfshaft from the transaxle
     

  4.  
  5. Dislodge the inner Tri-pot joint from the stub shaft retaining snapring on the transaxle. To do this, insert a prybar between the transaxle case and the inner Tri-pot joint and pry on Tri-pot joint.
  6.  

To install:

  1. Install the Tri-pot joint side of the halfshaft by performing the following procedure:
    1. Replace the inner Tri-pot joint retaining circlip and O-ring seal on the transaxle stub shaft. These components are not reusable and must be replaced whenever the halfshaft is removed.
    2.  
    3. Apply an even coat of grease on the splines of the inner Tri-pot joint, where the O-ring seats against the Tri-pot joint.
    4.  
    5. Grasp the inner joint in 1 hand and interconnecting shaft in the other. Align the inner Tri-pot joint spline with the stub shaft spline on the transaxle. Use a rocking motion with the inner Tri-pot joint to get it past the circlip on the transaxle stub shaft.
    6.  
    7. Continue pushing the Tri-pot joint onto transaxle stub shaft until it stops moving. The O-ring on the stub shaft should not be visible when the inner Tri-pot joint is fully installed. Check that the inner Tri-pot joint is locked in position by grasping the inner joint and pulling. If locked in position, the joint will not move on the stub shaft.
    8.  

  2.  
  3. Install the outer CV-joint into the hub and bearing assembly.
    WARNING
    The steering knuckle-to-strut assembly bolts are serrated and must not be turned during installation.. Also if the vehicle is equipped with eccentric strut assembly bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut bract.

  4.  
  5. Install or connect the following:

    Steering knuckle in the bracket of the damper assembly
     
    Strut damper-to-steering knuckle bolts and tighten to 65 ft. lbs. (88 Nm) plus an additional 1 / 4 turn
     
    Rotor, caliper. Tighten the caliper adapter bolts to 125 ft. lbs. (169 Nm)
     
    Washer and bearing-to-stub axle bolt and hand-tighten.
     
    Wheels
     

  6.  
  7. Apply the brakes and tighten the bearing-to-stub axle bolt to 180 ft. lbs. (244 Nm) and install the cotter pin.
  8.  
  9. Road test the vehicle to check for noise or vibration.
  10.  

 
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