shaft CHRYSLER CARAVAN 2002 Owner's Guide

the replacement outer CV joint assembly sealing boot
onto the interconnecting shaft.
(2) Install the outer CV joint assembly onto the
interconnecting shaft. Joint is installed on intercon-
necting shaft, by pushing interconnecting shaft into
outer CV joint, until retaining ring is seated in
groove on interconnecting shaft (Fig. 29). Verify that
the retaining ring is fully seated into groove on inter-
connecting shaft.(3)
Distribute 1/2 the amount of grease provided in
seal boot service package (DO NOT USE ANY OTHER
TYPE OF GREASE) into outer CV joint assembly hous-
ing. Put the remaining amount into the sealing boot.
(4) Install outer CV joint seal boot retaining
clamp, onto interconnecting shaft. Install replace-
ment outer CV joint sealing boot onto interconnecting
shaft.Outer CV joint seal boot MUST be posi-
tioned on interconnecting shaft, so that only
the thinnest (sight) groove on interconnecting
shaft is visible (Fig. 30).
(5) Place crimping tool C- 4975-A over bridge of
clamp (Fig. 31).
Fig. 31 Crimping Tool Installed on Sealing Boot Clamp
1 - SPECIAL TOOL C-4975-A
2 - INTERCONNECTING SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 28 Outer CV Joint Removal From
Interconnecting Shaft
1 - SPREAD RETAINING RING EARS AND PULL JOINT OFF
SHAFT
2 - RETAINING SNAP RING
3 - RETAINING RING
4 - OUTER C/V JOINT ASSEMBLY
5 - INTERCONNECTING SHAFT
Fig. 29 Outer CV Joint Installed On Interconnecting
Shaft
1 - INTERCONNECTING SHAFT
2 - RETAINING SNAP RING
3 - OUTER C/V JOINT ASSEMBLY
Fig. 30 Seal Boot Correctly Positioned On
Interconnecting Shaft
1 - SEALING BOOT
2 - INTERCONNECTING SHAFT THINNEST GROOVE
3 - INTERCONNECTING SHAFT
4 - BOOT CLAMP
RSHALF SHAFT - FRONT3-11
CV BOOT - OUTER (Continued)
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(6) Tighten nut on crimping tool C- 4975-A until
jaws on tool are closed completely together, face to
face (Fig. 32).
CAUTION: Seal boot must not be dimpled,
stretched, or out-of-shape in any way. If seal boot is
NOT shaped correctly, equalize pressure in seal and
shape it by hand.
(7) Position outer CV joint sealing boot into its
retaining groove on outer CV joint housing.
(8) Install sealing boot to outer CV joint retaining
clamp evenly on sealing boot.
(9) Place crimping tool C- 4975-A over bridge of
clamp (Fig. 33).
(10) Tighten nut on crimping tool C- 4975-A until
jaws on tool are closed completely together, face to
face (Fig. 34).
(11) Install the half shaft requiring boot replace-
ment back on the vehicle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT -
INSTALLATION)
Fig. 32 Sealing Boot Retaining Clamp Installed
1 - CLAMP
2 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 - INTERCONNECTING SHAFT
4 - SEALING BOOT
Fig. 33 Crimping Tool Installed on Sealing Boot
Clamp - Typical
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975-A
4 - SEALING BOOT
Fig. 34 Sealing Boot Retaining Clamp Installed -
Typical
1 - CLAMP
2 - TRIPOD HOUSING
3 - SPECIAL TOOL C-4975-A
4 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 - SEALING BOOT
3 - 12 HALF SHAFT - FRONTRS
CV BOOT - OUTER (Continued)
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OUTER CV JOINT BEARING
SHIELD
REMOVAL
(1) Clamp half shaft in a vise by the interconnect-
ing shaft.
(2) Using a drift (Fig. 35) tap around the entire
edge of the bearing shield until it is removed from
the outer CV joint.
INSTALLATION
(1) Install bearing shield by hand on outer CV
Joint so that it is installed squarely on the CV joint.
(2) Position installer, Special Tool C-4698-2, and
handle, Special Tool C-4698-1, on face of bearing
shield (Fig. 36).
CAUTION: If bearing shield is not installed flush
against the face of the outer CV joint, interference
with steering knuckle will occur when driveshaft is
installed.
(3) Using a hammer, drive the bearing shield on
the outer CV joint until it is flush against the front
of the outer CV joint (Fig. 37).
Fig. 35 Removing Bearing Shield from Outer CV
Joint
1 - DRIFT
2 - OUTER C/V JOINT
3 - BEARING SHIELD
Fig. 36 Special Tools for Installing Bearing Shield
1 - SPECIAL TOOL C-4698±2
2 - SPECIAL TOOL C-4698±1
3 - BEARING SHIELD
4 - OUTER C/V JOINT
Fig. 37 Correctly Installed Bearing Shield
1 - HAMMER
2 - SPECIAL TOOL C-4698±2
3 - BEARING SHIELD
4 - BEARING SEAL MUST BE FLUSH WITH FRONT OF OUTER
C/V JOINT
5 - SPECIAL TOOL C-4698±1
RSHALF SHAFT - FRONT3-13
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HALF SHAFT - REAR
TABLE OF CONTENTS
page page
HALF SHAFT - REAR
DESCRIPTION.........................14
DIAGNOSIS AND TESTING - HALF SHAFT....14
REMOVAL.............................15
INSTALLATION.........................15SPECIFICATIONS - HALF SHAFT - FRONT . . . 16
CV BOOT - INNER/OUTER
REMOVAL.............................17
INSTALLATION.........................18
HALF SHAFT - REAR
DESCRIPTION
The inner and outer joints of both half shaft
assemblies are tripod joints. The tripod joints are
true constant velocity (CV) joint assemblies, which
allow for the changes in half shaft length through
the jounce and rebound travel of the rear suspension.
On vehicles equipped with ABS brakes, the outer
CV joint is equipped with a tone wheel used to deter-
mine vehicle speed for ABS brake operation.
The inner tripod joint of both half shafts is bolted
rear differential assembly's output flanges. The outer
CV joint has a stub shaft that is splined into the
wheel hub and retained by a steel hub nut.
DIAGNOSIS AND TESTING - HALF SHAFT
VEHICLE INSPECTION
(1) Check for grease in the vicinity of the inboard
tripod joint and outboard CV joint; this is a sign of
inner or outer joint seal boot or seal boot clamp dam-
age.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could
be caused by one of the following conditions:
²Damaged outer CV or inner tripod joint seal
boot or seal boot clamps. This will result in the loss
and/or contamination of the joint grease, resulting in
inadequate lubrication of the joint.²Noise may also be caused by another component
of the vehicle coming in contact with the half shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following
conditions:
²A torn seal boot on the inner or outer joint of the
half shaft assembly.
²A loose or missing clamp on the inner or outer
joint of the half shaft assembly.
²A damaged or worn half shaft CV joint.
SHUDDER OR VIBRATION DURING ACCELERATION
This problem could be a result of:
²A worn or damaged half shaft inner tripod joint.
²A sticking tripod joint spider assembly (inner tri-
pod joint only).
²Improper wheel alignment. (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE)
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of:
²Foreign material (mud, etc.) packed on the back-
side of the wheel(s).
²Out of balance tires or wheels. (Refer to 22 -
TIRES/WHEELS - STANDARD PROCEDURE)
²Improper tire and/or wheel runout. (Refer to 22 -
TIRES/WHEELS - DIAGNOSIS AND TESTING)
3 - 14 HALF SHAFT - REARRS
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REMOVAL
(1) Lift vehicle on hoist so that the wheels hang
freely.
(2) Remove rear wheel.
(3) Remove cotter pin, nut lock, and wave washer
(Fig. 1).
(4) Remove hub nut and washer.
CAUTION: The half shaft outer CV joint, when
installed, acts as a bolt and secures the hub/bear-
ing assembly. If the vehicle is to be supported or
moved on its wheels, install and torque a bolt
through the hub. This will ensure that the hub/bear-
ing assembly cannot loosen.
(5) Remove inner half shaft retaining bolts (Fig. 2).(6) The half shaft is spring loaded. Compress inner
half shaft joint slightly and pull downward to clear
rear differential output flange. Then pull half shaft
assembly outward to remove (Fig. 3).
INSTALLATION
(1) Install the outer CV joint stub shaft through
the hub bearing (Fig. 4).
(2) The half shaft is spring loaded. Compress inner
half shaft joint slightly and push upward until the
inner CV joint flange engages the rear differential
output flange.
(3) Install the inner half shaft retaining bolts (Fig.
5). Torque the bolts to 61 N´m (45 ft.lbs.).
Fig. 1 Cotter Pin, Nut Lock, And Wave Washer
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
Fig. 2 Inner Half Shaft Bolts
1 - SHAFT
2 - FLANGE
Fig. 3 Half Shaft Removal
1 - BRAKE BACKING PLATE
2 - HALF SHAFT
Fig. 4 Half Shaft Installation
1 - BRAKE BACKING PLATE
2 - HALF SHAFT
RSHALF SHAFT - REAR3-15
HALF SHAFT - REAR (Continued)
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(4) Install the half shaft washer and hub nut.
Torque the hub nut to 244 N´m (180 ft.lbs.).
(5) Install the wave washer, nut lock, and a new
cotter pin (Fig. 6). Be sure to wrap the cotter pin
prongs tightly around the hub nut lock.(6) Install rear wheel. Torque the lug nuts to 135
N´m (100 ft.lbs.).
SPECIFICATIONS - HALF SHAFT - FRONT
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Nut, Hub 244 180 -
Nuts, Rear Wheel Lug 135 100 -
Bolt, Half Shaft to Output Flange 61 45 -
Fig. 5 Inner Half Shaft Bolts
1 - SHAFT
2 - FLANGE
Fig. 6 Cotter Pin, Nut Lock, And Wave Washer
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
3 - 16 HALF SHAFT - REARRS
HALF SHAFT - REAR (Continued)
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CV BOOT - INNER/OUTER
REMOVAL
(1) Remove half shaft from vehicle. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL)
(2) Clamp the half shaft into a suitable vise with
protective jaws clamped onto the interconnecting
shaft (Fig. 7).
(3) Remove the large and small diameter retaining
clamps holding the CV boot to the CV joint and the
interconnecting shaft (Fig. 8).(4) Pull the boot back from the CV joint (Fig. 9).
(5) Remove the CV housing from the interconnect-
ing shaft and tripod assembly (Fig. 10).
Fig. 7 Clamp Shaft In Soft Jawed Vice
1 - HALF SHAFT BOOT
2 - HALF SHAFT
3 - VISE
Fig. 8 Remove Boot Clamps
1 - HALF SHAFT BOOT
2 - CLAMP
Fig. 9 Pull Back Boot
1 - HALF SHAFT BOOT
2 - HALF SHAFT JOINT
Fig. 10 Remove CV Housing
1 - HALF SHAFT JOINT HOUSING
2 - BOOT
RSHALF SHAFT - REAR3-17
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(6) Remove the snap-ring holding the tripod
assembly onto the interconnecting shaft (Fig. 11).
(7) Remove the tripod assembly from the intercon-
necting shaft (Fig. 12).(8) Remove the CV boot from the interconnecting
shaft (Fig. 13).
INSTALLATION
(1) Clean the interconnecting shaft and inner CV
joint of any residual grease and dirt.
(2) Slide the new small diameter retaining clamp
onto the interconnecting shaft.
(3) Install the CV boot onto the interconnecting
shaft (Fig. 14).
Fig. 12 Slide Tripod Off The Shaft
1 - TRIPOD ASSEMBLY
2 - AXLE SHAFT
3 - HALF SHAFT BOOT
Fig. 11 Remove Snap-Ring
1 - SNAP RING
2 - HALF SHAFT BOOT
3 - TRIPOD ASSEMBLY
4 - SNAP RING PLIERS
Fig. 13 Remove Boot
1 - HALF SHAFT BOOT
Fig. 14 Install CV Boot Onto Interconnecting Shaft
1 - HALF SHAFT BOOT
3 - 18 HALF SHAFT - REARRS
CV BOOT - INNER/OUTER (Continued)
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(4) Install the tripod assembly onto the intercon-
necting shaft (Fig. 15).
(5) Install the snap-ring to hold the tripod assem-
bly onto the interconnecting shaft (Fig. 16).(6) Install the new large diameter retaining clamp
onto the CV joint housing.
(7) Distribute 1/2 the amount of grease provided in
the seal boot service package (DO NOT USE ANY
OTHER TYPE OF GREASE) into tripod housing. Put
the remaining amount into the sealing boot.
(8) Install the CV housing onto the interconnecting
shaft and tripod assembly (Fig. 17).
(9) Clamp the half shaft into a suitable vise with
protective jaws clamped onto the interconnecting
shaft.
Fig. 16 Install Snap-Ring
1 - SNAP RING
2 - HALF SHAFT BOOT
3 - TRIPOD ASSEMBLY
4 - SNAP RING PLIERS
Fig. 15 Slide Tripod Onto The Interconnecting Shaft
1 - TRIPOD ASSEMBLY
2 - AXLE SHAFT
3 - HALF SHAFT BOOT
Fig. 17 Install CV Housing
1 - HALF SHAFT JOINT HOUSING
2 - BOOT
RSHALF SHAFT - REAR3-19
CV BOOT - INNER/OUTER (Continued)
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(10) Position the inner CV joint boot on intercon-
necting shaft so the raised bead on the inside of the
small diameter end of the seal boot is in mating
groove on interconnecting shaft (Fig. 18).
(11) Install inner CV joint seal boot to intercon-
necting shaft clamp evenly on sealing boot.
(12) Place crimping tool C-4975-A over bridge of
clamp (Fig. 19).
(13) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 20).
CAUTION: The boot must not be dimpled, stretched
or out of shape in any way. If boot is NOT shaped
correctly, equalize pressure in boot and shape it by
hand.
(14) Position CV boot into the CV housing retain-
ing groove. Install the boot large diameter retaining
clamp evenly onto the boot.
(15) Clamp the CV joint boot to the CV joint, using
required procedure for type of boot clamp application.
Fig. 18 Sealing Boot Installation on Interconnecting
Shaft
1 - SEALING BOOT
2 - RAISED BEAD IN THIS AREA OF SEALING BOOT
3 - GROOVE
4 - INTERCONNECTING SHAFT
Fig. 19 Crimping Tool Installed on Sealing Boot
Clamp - Typical
1 - SPECIAL TOOL C-4975-A
2 - INTERCONNECTING SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 20 Sealing Boot Retaining Clamp Installed -
Typical
1 - CLAMP
2 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 - INTERCONNECTING SHAFT
4 - SEALING BOOT
3 - 20 HALF SHAFT - REARRS
CV BOOT - INNER/OUTER (Continued)
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