Pacifica 2006-2008

Halfshafts

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CV-Joints



Overhaul
Front
Inner (Tri-Pot) Joint
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the halfshaft and retaining clamps.
  6.  
  7. Slide the boot down the shaft away from the tri-pot housing.
    NOTE
    When separating the spider joint from the tri-pot joint housing, hold the rollers in place on the trunnions to prevent the rollers and needle bearings from falling away.

  8.  
  9. Carefully, slide the shaft/spider assembly from the tri-pot housing.
  10.  
  11. Remove the spider assembly-to-shaft snapring; then, slide the spider assembly off the shaft.
    WARNING
    If necessary, tap the spider assembly off the shaft using a brass drift; be careful not to hit the outer bearings.

  12.  
  13. Slide the boot off the shaft.
  14.  
  15. Thoroughly, inspect all parts for signs of excessive wear; if necessary, replace the halfshaft.
    NOTE
    Component parts are not serviceable and must be replaced as an assembly.



    Click image to see an enlarged view

    Fig. Slide the boot down the shaft away from the tri-pot housing



    Click image to see an enlarged view

    Fig. Remove the spider assembly-to-shaft snapring; then, slide the spider assembly off the shaft



    Click image to see an enlarged view

    Fig. Securing the halfshaft boot clamp

  16.  

To install:

  1. Slide the inner tri-pot boot clamp and boot onto the shaft; then, position the boot so that only the thinnest (sight) groove is visible on the shaft.
  2.  
  3. Install the spider assembly onto the shaft just far enough so that the snapring can be installed.
    WARNING
    If necessary, tap the spider assembly onto the shaft using a brass drift; be careful not to hit the outer bearings.

  4.  
  5. Install the snapring onto the shaft; make sure that the snapring is fully seated in the groove.
  6.  
  7. If installing a new boot, distribute 1 / 2 of the grease in the service package inside the tri-pot housing and the other 1 / 2 inside the boot.
  8.  
  9. Carefully, slide the spider assembly and shaft into the tri-pot housing.
  10.  
  11. Position the inner boot clamp evenly on the sealing boot.
  12.  
  13. Using the Crimper tool C-4975, 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.

  14.  
  15. Position the boot onto the tri-pot housing retaining groove and install the retaining clamp evenly on the boot.
  16.  
  17. Using the Crimper tool C-4975, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
  18.  
  19. Install the halfshaft into the vehicle.
  20.  

Outer CV Joint
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the halfshaft and the retaining clamps.
  6.  
  7. Slide the boot down the shaft away from the CV-joint housing.
  8.  
  9. Remove the grease to expose the CV-joint-to-shaft retaining ring.
  10.  
  11. Spread the snapring ears apart and slide the CV-joint assembly off of the shaft.
  12.  
  13. Slide the boot off the shaft.
  14.  
  15. Thoroughly, clean and inspect all parts for signs of excessive wear; if necessary, replace the halfshaft.
    NOTE
    Component parts are not serviceable and must be replaced as an assembly.



    Click image to see an enlarged view

    Fig. The latch type boot clamp is tightened as illustrated-..



    Click image to see an enlarged view

    Fig. -. and should look like this when properly installed

  16.  

To install:

  1. Slide the outer CV-joint boot clamp and boot onto the shaft; then, position the boot so that only the thinnest (sight) groove is visible on the shaft.
  2.  
  3. Slide the outer CV-joint assembly on the shaft, spread the snapring ears, position the CV-joint and verify that the snapring is fully seated in the shaft groove.
  4.  
  5. If installing a new boot, distribute 1 / 2 of the grease in the service package into the CV-joint housing and the other 1 / 2 inside the boot.
  6.  
  7. Position the outer boot clamp evenly on the sealing boot.
  8.  
  9. Using the Crimper tool C-4975, 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 CV-joint housing retaining groove and install the retaining clamp evenly on the boot.
  12.  
  13. Using the Crimper tool C-4975, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
  14.  
  15. Install the halfshaft into the vehicle.
  16.  

Rear
Inner (Tri-Pot) Joint
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the halfshaft and retaining clamps.
  6.  
  7. Slide the boot down the shaft away from the tri-pot housing.
    NOTE
    When separating the spider joint from the tri-pot joint housing, hold the rollers in place on the trunnions to prevent the rollers and needle bearings from falling away.

  8.  
  9. Carefully, slide the shaft/spider assembly from the tri-pot housing.
  10.  
  11. Remove the spider assembly-to-shaft snapring; then, slide the spider assembly off the shaft.
    WARNING
    If necessary, tap the spider assembly off the shaft using a brass drift; be careful not to hit the outer bearings.

  12.  
  13. Slide the boot off the shaft.
  14.  
  15. Thoroughly, inspect all parts for signs of excessive wear; if necessary, replace the halfshaft.
    NOTE
    Component parts are not serviceable and must be replaced as an assembly.



    Click image to see an enlarged view

    Fig. Slide the boot down the shaft away from the tri-pot housing



    Click image to see an enlarged view

    Fig. Remove the spider assembly-to-shaft snapring; then, slide the spider assembly off the shaft



    Click image to see an enlarged view

    Fig. Securing the halfshaft boot clamp

  16.  

To install:

  1. Slide the inner tri-pot boot clamp and boot onto the shaft; then, position the boot so that only the thinnest (sight) groove is visible on the shaft.
  2.  
  3. Install the spider assembly onto the shaft just far enough so that the snapring can be installed.
    WARNING
    If necessary, tap the spider assembly onto the shaft using a brass drift; be careful not to hit the outer bearings.

  4.  
  5. Install the snapring onto the shaft; make sure that the snapring is fully seated in the groove.
  6.  
  7. If installing a new boot, distribute 1 / 2 of the grease in the service package inside the tri-pot housing and the other 1 / 2 inside the boot.
  8.  
  9. Carefully, slide the spider assembly and shaft into the tri-pot housing.
  10.  
  11. Position the inner boot clamp evenly on the sealing boot.
  12.  
  13. Using the Crimper tool C-4975, 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.

  14.  
  15. Position the boot onto the tri-pot housing retaining groove and install the retaining clamp evenly on the boot.
  16.  
  17. Using the Crimper tool C-4975, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
  18.  
  19. Install the halfshaft into the vehicle.
  20.  

Outer CV Joint
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the halfshaft and the retaining clamps.
  6.  
  7. Slide the boot down the shaft away from the CV-joint housing.
  8.  
  9. Remove the grease to expose the CV-joint-to-shaft retaining ring.
  10.  
  11. Spread the snapring ears apart and slide the CV-joint assembly off of the shaft.
  12.  
  13. Slide the boot off the shaft.
  14.  
  15. Thoroughly, clean and inspect all parts for signs of excessive wear; if necessary, replace the halfshaft.
    NOTE
    Component parts are not serviceable and must be replaced as an assembly.



    Click image to see an enlarged view

    Fig. The latch type boot clamp is tightened as illustrated-..



    Click image to see an enlarged view

    Fig. -. and should look like this when properly installed

  16.  

To install:

  1. Slide the outer CV-joint boot clamp and boot onto the shaft; then, position the boot so that only the thinnest (sight) groove is visible on the shaft.
  2.  
  3. Slide the outer CV-joint assembly on the shaft, spread the snapring ears, position the CV-joint and verify that the snapring is fully seated in the shaft groove.
  4.  
  5. If installing a new boot, distribute 1 / 2 of the grease in the service package into the CV-joint housing and the other 1 / 2 inside the boot.
  6.  
  7. Position the outer boot clamp evenly on the sealing boot.
  8.  
  9. Using the Crimper tool C-4975, 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 CV-joint housing retaining groove and install the retaining clamp evenly on the boot.
  12.  
  13. Using the Crimper tool C-4975, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).
  14.  
  15. Install the halfshaft into the vehicle.
  16.  

Removal & Installation



Front
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the cotter pin and nut lock retainer.
  8.  
  9. Remove the wave washer from the end of the halfshaft.
  10.  
  11. Remove the tire and wheel assembly.
  12.  
  13. Loosen and remove the halfshaft nut.
    NOTE
    Apply the vehicle-s brakes to keep the hub from turning in order to remove the nut.

  14.  
  15. Remove the two disc brake caliper adapter to steering knuckle attaching bolts.

    Click image to see an enlarged view

    Fig. Exploded view of the front halfshaft and related components-typical

  16.  
  17. Remove the caliper assembly. Properly support the caliper as not to cause damage to the brake line hose.
  18.  
  19. Remove the brake rotor.
  20.  
  21. Remove the steering knuckle to strut retaining bolts from the steering knuckle.
  22.  
  23. Pull the steering knuckle from the strut clevis bracket.
    NOTE
    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 and bearing assembly in the steering knuckle. The end of the halfshaft must be supported.

  24.  
  25. Pull the steering knuckle assembly and down and away from the outer CV joint of the halfshaft assembly while pulling the joint out of the hub bearing.
  26.  
  27. Support the outer end of the halfshaft. Insert a prybar between the inner tripod joint and the transaxle case. Pry against the inner tripod joint until the snapring is disengaged from the transaxle side gear.

    Click image to see an enlarged view

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

  28.  
  29. Hold the inner tripod joint and interconnecting shaft of the halfshaft.
  30.  
  31. Remove the inner tripod joint from the transaxle by pulling it straight out of the transaxle side gear and transaxle oil seal.
    NOTE
    When removing the tripod joint, do not let the spline or snapring drag across the sealing lip of the transaxle to tripod joint oil seal.

  32.  

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 bracket.

  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.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the cotter pin and nut lock retainer.
  8.  
  9. Remove the wave washer from the end of the halfshaft.
  10.  
  11. Remove the tire and wheel assembly.
  12.  
  13. Loosen and remove the halfshaft nut.
    NOTE
    Apply the vehicle-s brakes to keep the hub from turning in order to remove the nut.

  14.  
  15. Remove the two disc brake caliper adapter to steering knuckle attaching bolts.
  16.  
  17. Remove the caliper assembly. Properly support the caliper as not to cause damage to the brake line hose.
  18.  
  19. Remove the brake rotor.
  20.  
  21. Remove the steering knuckle to strut retaining bolts from the steering knuckle.
  22.  
  23. Pull the steering knuckle from the strut clevis bracket.
    NOTE
    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 and bearing assembly in the steering knuckle. The end of the halfshaft must be supported.

  24.  
  25. Pull the steering knuckle assembly and down and away from the outer CV joint of the halfshaft assembly while pulling the joint out of the hub bearing.
  26.  
  27. Support the outer end of the halfshaft. Insert a prybar between the inner tripod joint and the transaxle case. Pry against the inner tripod joint until the snapring is disengaged from the transaxle side gear.
  28.  
  29. Pull the steering knuckle from the strut clevis bracket.
  30.  
  31. 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.
  32.  
  33. Remove the bolts at the heat shield and remove the heat shield, if equipped.
  34.  
  35. Remove the three bolts holding the midshaft bearing to the block.
  36.  
  37. Remove the intermediate shaft.
  38.  

To install:


NOTE
A rubber coated washer should be used on the outer CV joint stem during assembly.

  1. Installation is the reverse of the removal procedure.
    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 bracket.

  2.  
  3. Road test the vehicle to check for noise or vibration.
  4.  

Rear

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



    Click image to see an enlarged view

    Fig. 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.
  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.  

Refer to 2005-2006 rear halfshaft removal and installation

 
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