Rendezvous 2006-2007

Halfshafts

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CV-Joints



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

    Halfshaft
     
    Large seal retaining clamp from the CV-joint and discard the clamp
     
    Swage ring by using a hand grinder to cut through it. Do not damage the axle shaft with the grinder
     
    Halfshaft outboard seal from the CV-joint outer race and slide the seal away from the joint
     
    CV-joint and boot from the halfshaft and discard the boot
     

  4.  
  5. Place a brass drift against the CV-joint cage and gently tap on it until it tilts. Remove the chrome alloy ball. Tilt the cage in the opposite direction and remove the ball. Continue to rotate the cage until all six alloy balls have been removed.
  6.  
  7. Pivot the cage and inner race 90 degrees to the center line of the of the outer race. Align the cage windows with the outer race lands. Lift the cage and the inner race out of the CV-joint.
  8.  
  9. Remove the inner race from the cage by rotating the race upward.
  10.  
  11. Clean the grease and contaminates with cleaning solvent from the inner/outer races; CV-joint cage and the alloy balls.
  12.  
  13. Remove any rust from the boot mounting area and clean the halfshaft bar.
  14.  

To assemble:

  1. Coat the inner and outer race grooves with grease and align the inner race with the windows of the cage.
  2.  
  3. Insert the inner race to the cage by rotating the race downward.
  4.  
  5. Insert the cage and inner race into the outer race.
  6.  
  7. Install the six alloy balls into the cage by tilting the cage. Repeat this process until all the balls are in place.
  8.  
  9. Pack the CV boot and joint with the grease supplied in the kit.
  10.  
  11. Install or connect the following:
    NOTE
    Make certain that the retaining ring side of the inner race faces the halfshaft bar before installation.



    New boot clamp onto the boot
     
    CV boot on to the halfshaft bar and position the small end of the boot into the groove on the halfshaft bar. Secure the clamp to the boot with a Seal Clamp tool J 35910. Torque the clamp to 100 ft. lbs. (136 Nm).
     
    Swage ring over the large diameter of the boot by pinching the ring into an oval shape
     

  12.  
  13. Slide the joint onto the halfshaft with the retaining snapring inside of the inner race. The race is properly seated when it snaps into place. Pull on the CV-joint to verify full engagement.
  14.  
  15. Install the large diameter of the boot with the large swage ring in place over the outside edge of the joint outer race.
  16.  
  17. Clamp the boot tightly to the outer race with the large swage ring by mounting Split Plate Swage Clamp tool J 36652 in a vise.
  18.  
  19. Position the outboard end of the halfshaft in the bottom of the tool.
  20.  
  21. Align the CV boot, joint and swage ring.
  22.  
  23. Install the top half of the tool and align the swage ring and clamp. Install the bolts to the top of the tool and tighten snugly. Tighten each bolt an additional 180 degrees. Alternate between the bolts until both sides of the top portion of the tool touch the bottom half.
  24.  
  25. Loosen the bolts and remove the split plate swage clamp tool.
  26.  
  27. Install the halfshaft.
  28.  
  29. Road test the vehicle and make certain there are no abnormal noises in the front end.
  30.  
  31. Check and adjust the alignment if necessary.
  32.  

Removal & Installation



These procedures requires the use of the following special tools. Slide Hammer Tool No. J 2619-01, Axle Shaft Remover Extension J 29794, Axle Shaft Puller J 33008-A and Wheel Hub Remover J 42129.

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

    Front wheel
     
    Splash shield
     
    Stabilizer shaft link
     
    Wheel Speed Sensor (WSS) electrical connector
     

  4.  
  5. Insert a drift into the caliper and into the rotor to prevent the rotor from turning.
    NOTE
    Note the installed position of the 2-piece washer before removing it. The ramped sides must face each other when installing the washer.



    Halfshaft nut and the ramped 2-piece washer. Discard the nut.
     
    Tie rod end from the steering knuckle; Do NOT loosen the tie rod jam nut
     
    Lower ball joint from the steering knuckle
     

  6.  
  7. Install wheel hub removal tool (J 42129) onto the hub and secure with the lug nuts. Use the tool to disengage the halfshaft from the hub and bearing, then support the shaft.

    Click image to see an enlarged view

    Fig. Wheel hub removal tool

  8.  
  9. Assemble the Slide Hammer Tool No. J 2619-01, Axle Shaft Remover Extension J 29794 and Axle Shaft Puller J 33008-A. Use the assembled tool to disengage the halfshaft from the transaxle.

    Click image to see an enlarged view

    Fig. Assemble the special tools to separate the halfshaft from the transaxle

  10.  
  11. Remove or disconnect the following:

    Halfshaft from the vehicle
     
    Halfshaft retaining ring and discard. On the right halfshaft, the retaining ring is on the splined shaft of the inner tripot housing. On the left halfshaft, the retaining ring is on the splined transmission output shaft.
     

  12.  

To install:

  1. Install or connect the following:
    WARNING
    Do not pull on the halfshaft bar.



    New halfshaft retaining ring
     
    Halfshaft to the transaxle. Push the halfshaft into the transaxle until it is fully seated. Pull on the tri-pot joint to verify that the retaining ring is fully engaged.
     



    Halfshaft to the hub and bearing.
     
    Ball joint to the steering knuckle
     
    2-piece washer. Make sure the ramped sides of the washer are facing each other.
     
    Drift through the caliper and into the rotor to prevent it from turning
     
    New halfshaft nut. Torque it to 192 ft. lbs. (260 Nm).
     
    Stabilizer shaft link. Torque the nut to 17 ft. lbs. (23 Nm).
     
    WSS electrical connector
     
    Splash shield
     
    Front wheel
     

  2.  
  3. Check the transaxle fluid level. Check and adjust the alignment as needed.
  4.  
  5. Road test the vehicle and check for any abnormal noise.

    Click image to see an enlarged view

    Fig. Install the left side halfshaft

  6.  

 
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