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



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Apply the parking brake.
  4.  
  5. Remove or disconnect the following:

    Rear wheel
     
    Halfshaft nut and discard
     

  6.  
  7. Release the parking brake.

    Brake caliper bracket and support it with a piece of wire
     
    Parking brake cable routing bracket nut, if necessary
     
    Rear tie rod end-to-knuckle bolt; DO NOT loosen the tie rod end jam nut
     
    Parking brake cable bracket-to-knuckle bolts; loosen only.
     
    Wheel Speed Sensor (WSS) electrical connector
     

  8.  
  9. Install the Wheel Hub Removal Tool No. K 42129 onto the wheel hub and secure with wheel nuts. Begin to disengage the halfshaft from the hub and bearing.

    Bolt and nut securing the upper control arm to the suspension knuckle
     
    Halfshaft completely from the hub and bearing
     

  10.  
  11. Reposition the suspension knuckle toward the rear of the vehicle.
    NOTE
    Support the halfshaft until it is completely removed from the vehicle.



    Tool from the wheel hub
     

  12.  
  13. Assemble the Slide Hammer Tool No. J 2619-01, Axle Shaft Remover Extension J 29794 and Axle Shaft Puller J 33008-A. Install the Axle Shaft Puller evenly onto the rear beveled surface of the halfshaft inner joint housing.
    NOTE
    The differential output shaft oil seal must be replaced when removing the rear wheel drive shaft.



    Halfshaft from the rear axle differential using the assembled tools
     
    Halfshaft from the vehicle
     



    Halfshaft oil seal
     

  14.  

To install:


WARNING
Support the wheel drive shaft until it is completely installed.

  1. Install or connect the following:
    WARNING
    Be careful not to damage the differential output shaft oil seal.



    Halfshaft to the differential output shaft. Carefully align and guide the halfshaft onto the differential output shaft.
     



    Halfshaft fully onto the differential output shaft using light force. Make sure it is fully seated on the differential output shaft retaining ring by grasping the inner tripot housing and pulling outward. Do not pull on the wheel drive shaft bar. The halfshaft will remain firmly in place when properly engaged.
     

  2.  
  3. Begin to position the suspension knuckle to the halfshaft. Align and carefully guide the halfshaft into the hub and bearing but do not seat fully.

    Suspension knuckle to the upper control arm
     
    Bolt and nut to the upper control arm/suspension knuckle assembly. Torque the bolt to 63 ft. lbs. (85 Nm).
     
    Parking brake cable bracket.
     
    Tie rod to the knuckle. Tighten the bolt to 63 ft. lbs. (85 Nm).
     
    Brake caliper bracket
     
    WSS electrical connector
     
    Parking brake cable routing bracket, if removed. Tighten the nuts to 89 inch lbs. (10 Nm).
     

  4.  
  5. Set the park brake.

    New halfshaft nut. Tighten to 192 ft. lbs. (260 Nm).
     
    Wheel
     

  6.  
  7. Lower the vehicle and release the parking brake.
  8.  

 
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