boot CHRYSLER VOYAGER 2001 Owner's Manual

CAUTION: Do not attempt to install a normal grease
zirc in the ball joint and lubricate the joint through
the zirc fitting.
(6) Reinstall steering knuckle on vehicle. (Refer to
2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
2a - 2 FRONT SUSPENSIONRG
LOWER BALL JOINT SEAL BOOT (Continued)

DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT.....................1
HALF SHAFT - REAR.....................16PROPELLER SHAFT......................24
REAR DRIVELINE MODULE................26
HALF SHAFT - FRONT
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT
DESCRIPTION............................1
DIAGNOSIS AND TESTING..................1
HALF SHAFT...........................1
REMOVAL...............................2
INSTALLATION............................5
SPECIFICATIONS.........................7
CV BOOT - INNER
REMOVAL...............................7INSTALLATION............................8
CV BOOT - OUTER
REMOVAL..............................11
INSTALLATION...........................12
OUTER CV JOINT BEARING SHIELD
REMOVAL..............................14
INSTALLATION...........................14
HALF SHAFT - FRONT
DESCRIPTION
All vehicles use an unequal length half shaft sys-
tem (Fig. 1).
The left half shaft uses a tuned rubber damper
weight. When replacing the left half shaft, be sure
the replacement half shaft has the same damper
weight as the original.
All half shaft assemblies use the same type of
inner and outer joints. The inner joint of both half
shaft assemblies is a tripod joint, and the outer joint
of both half shaft assemblies is a Rzeppa joint. Both
tripod joints and Rzeppa joints are true constant
velocity (CV) joint assemblies. The inner tripod joint
allows for the changes in half shaft length through
the jounce and rebound travel of the front suspen-
sion.
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 splined
into the transaxle side gears. The inner tripod joints
are retained in the side gears of the transaxle usinga snap ring located in the stub shaft of the tripod
joint. 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.
(2) A light film of grease may appear on the right
inner tripod joint seal boot; this is considered normal
and should not require replacement of the seal boot.
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.
RSDIFFERENTIAL & DRIVELINE3-1

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)
REMOVAL
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist.
(2) Remove the cotter pin and nut lock (Fig. 2)
from the end of the half shaft.
(3) Remove the wave washer (Fig. 3) from the end
of the half shaft.
(4) Remove the wheel and tire assembly from the
vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL)
(5) With the vehicle's brakes applied to keep hub
from turning,loosen and removethe half shaft
nut.
(6) Remove the two front disc brake caliper
adapter to steering knuckle attaching bolts (Fig. 4).
Fig. 1 Unequal Length Half Shaft System
1 - STUB AXLE
2 - OUTER C/V JOINT
3 - OUTER C/V JOINT BOOT
4 - TUNED RUBBER DAMPER WEIGHT
5 - INTERCONNECTING SHAFT
6 - OUTER C/V JOINT BOOT
7 - STUB AXLE
8 - OUTER C/V JOINT9 - RIGHT HALFSHAFT
10 - INNER TRIPOD JOINT BOOT
11 - INNER TRIPOD JOINT
12 - INNER TRIPOD JOINT
13 - INNER TRIPOD JOINT BOOT
14 - INTERCONNECTING SHAFT & LEFT HALFSHAFT
3 - 2 HALF SHAFT - FRONTRS
HALF SHAFT - FRONT (Continued)

SPECIFICATIONS
SPECIFICATIONS - HALF SHAFT - FRONT
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolts, Caliper Adapter to Knuckle 169 125 -
Nut, Hub 244 180 -
Nuts, Front Wheel Lug 135 100 -
Nut, Tie Rod End to Knuckle 75 55 -
Nut, Strut Clevis to Knuckle 81 +90É 60 +90É -
CV BOOT - INNER
REMOVAL
(1) Remove the half shaft requiring boot replace-
ment from the vehicle. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/HALF SHAFT - REMOVAL)
(2) Remove large boot clamp which retains inner
tripod joint sealing boot to tripod joint housing and
discard.
(3) Remove small clamp which retains inner tripod
joint sealing boot to interconnecting shaft and dis-
card.
(4) Remove the sealing boot from the tripod hous-
ing and slide it down the interconnecting shaft.
CAUTION: When removing the tripod joint housing
from the spider assembly, hold the bearings in
place on the spider trunions to prevent the bearings
from falling away.
(5) Slide the tripod joint housing off the spider
assembly and the interconnecting shaft (Fig. 15).
(6) Remove snap-ring which retains spider assem-
bly to interconnecting shaft (Fig. 16).Do not hit the
outer tripod bearings in an attempt to remove
spider assembly from interconnecting shaft.
(7) Remove the spider assembly from interconnect-
ing shaft. If spider assembly will not come off inter-
connecting shaft by hand, it can be removed by
tapping spider assembly with a brass drift (Fig. 17).(8) Slide sealing boot off interconnecting shaft.
(9) Thoroughly clean and inspect spider assembly,
tripod joint housing, and interconnecting shaft for
any signs of excessive wear.If any parts show
signs of excessive wear, the half shaft assembly
will require replacement. Component parts of
these half shaft assemblies are not serviceable.
Fig. 15 Spider Assembly Removal from Tripod Joint
Housing
1 - TRIPOD JOINT HOUSING
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
RSHALF SHAFT - FRONT3-7
HALF SHAFT - FRONT (Continued)

INSTALLATION
(1) Slide inner CV joint seal boot retaining clamp,
onto the interconnecting shaft. Then, slide the
replacement inner CV joint sealing boot onto the
interconnecting shaft.Inner CV joint seal boot
MUST be positioned on interconnecting 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).(2) Install spider assembly onto interconnecting
shaft (Fig. 19). Spider assembly must be installed on
interconnecting shaft far enough to fully install spi-
der retaining snap-ring. If the spider assembly will
not fully install on interconnecting shaft by hand, it
can be installed by tapping the spider body with a
brass drift (Fig. 20).Do not hit the outer tripod
bearings in an attempt to install spider assem-
bly on interconnecting shaft.
(3) Install the spider assembly to interconnecting
shaft retaining snap-ring into groove on end of inter-
connecting shaft (Fig. 21). Be sure the snap-ring is
fully seated into groove on interconnecting shaft.
Fig. 16 Spider Assembly Retaining Snap-Ring
1 - INTERCONNECTING SHAFT
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP RING
Fig. 17 Spider Assembly Removal from
Interconnecting Shaft
1 - SPIDER ASSEMBLY
2 - DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN
REMOVING SPIDER ASSEMBLY
3 - BRASS DRIFT
4 - INTERCONNECTING SHAFT
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 Spider Assembly Installation on
Interconnecting Shaft
1 - SPIDER ASSEMBLY
2 - INTERCONNECTING SHAFT
3 - 8 HALF SHAFT - FRONTRS
CV BOOT - INNER (Continued)

(4) 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.
(5) Align tripod housing with spider assembly and
then slide tripod housing over spider assembly and
interconnecting shaft (Fig. 22).(6) Install inner CV joint seal boot to interconnect-
ing shaft clamp evenly on sealing boot.
(7) Place crimping tool C-4975-A over bridge of
clamp (Fig. 23).
(8) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 24).
Fig. 20 Installing Spider Assembly on
Interconnecting Shaft
1 - DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER
ASSEMBLY
2 - SPIDER ASSEMBLY
3 - INTERCONNECTING SHAFT
4 - BRASS DRIFT
Fig. 21 Spider Assembly Retaining Snap-Ring
Installed
1 - INTERCONNECTING SHAFT
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP RING
Fig. 22 Installing Tripod Housing on Spider
Assembly
1 - TRIPOD JOINT HOUSING
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
Fig. 23 Crimping Tool Installed on Sealing Boot
Clamp - Typical
1 - SPECIAL TOOL C-4975A
2 - INTERCONNECTING SHAFT
3 - CLAMP
4 - SEALING BOOT
RSHALF SHAFT - FRONT3-9
CV BOOT - INNER (Continued)

CAUTION: Seal must not be dimpled, stretched or
out of shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
(9) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
(10) Position trilobal boot to interface with the tri-
pod housing. The lobes of the boot must be properly
aligned with the recess's of the tripod housing.
CAUTION: The following positioning procedure
determines the correct air pressure inside the inner
CV joint assembly prior to clamping the sealing
boot to inner CV joint housing. If this procedure is
not done prior to clamping sealing boot to CV joint
housing sealing boot durability can be adversely
affected.
CAUTION: When venting the inner CV joint assem-
bly, use care so that the inner CV sealing boot does
not get punctured, or in any other way damaged. If
sealing boot is punctured, or damaged in any way
while being vented, the sealing boot can not be
used.(11) Insert a trim stick between the CV joint hous-
ing and the sealing boot insert to vent inner CV joint
assembly (Fig. 25).When inserting trim stick
between tripod housing and sealing boot
ensure trim stick is held flat and firmly against
the tripod housing. If this is not done damage
to the sealing boot can occur.
(12) With trim stick inserted between sealing boot
insert and the CV joint housing, position the inter-
connecting shaft so it is at the center of its travel in
the tripod joint housing. Remove the trim stick from
between the sealing boot insert and the CV joint
housing.This procedure will equalize the air
pressure in the CV joint, preventing premature
sealing boot failure.
(13) Clamp CV joint sealing boot to CV joint, using
required procedure for type of boot clamp application.
CRIMP TYPE BOOT CLAMP
If seal boot uses crimp type boot clamp, use the fol-
lowing procedure to install the retaining clamp.
(1) Place crimping tool C-4975-A over bridge of
clamp (Fig. 26).
(2) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 27).
Fig. 24 Sealing Boot Retaining Clamp Installed -
Typical
1 - CLAMP
2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 - INTERCONNECTING SHAFT
4 - SEALING BOOT
Fig. 25 Trim Stick Inserted for Venting CV Joint
1 - INNER TRIPOD JOINT SEALING BOOT
2 - SEALING BOOT CLAMP
3 - INNER TRIPOD JOINT HOUSING
4 - TRIM STICK
3 - 10 HALF SHAFT - FRONTRS
CV BOOT - INNER (Continued)

LATCHING TYPE BOOT CLAMP
If seal boot uses low profile latching type boot
clamp, use the following procedure to install the
retaining clamp.
(1) Place prongs of clamp locking tool in the holes
of the clamp (Fig. 28).
(2) Squeeze tool together until top band of clamp is
latched behind the two tabs on lower band of clamp
(Fig. 29).(3) Install the half shaft back into the vehicle.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
CV BOOT - OUTER
REMOVAL
(1) Remove half shaft assembly requiring boot
replacement from vehicle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
Fig. 26 Crimping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975A
4 - SEALING BOOT
Fig. 27 Sealing Boot Retaining Clamp Installed
1 - CLAMP
2 - TRIPOD HOUSING
3 - SPECIAL TOOL C-4975A
4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 - SEALING BOOT
Fig. 28 Clamping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - SPECIAL TOOL YA3050
3 - SEALING BOOT
Fig. 29 Sealing Boot Clamp Correctly Installed
1 - INNER TRIPOD JOINT HOUSING
2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS
SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP
3 - SEALING BOOT
RSHALF SHAFT - FRONT3-11
CV BOOT - INNER (Continued)

(2) Remove large boot clamp retaining CV joint
sealing boot to CV joint housing (Fig. 30) and dis-
card.
(3) Remove small clamp that retains outer CV
joint sealing boot to interconnecting shaft and dis-
card.
(4) Remove sealing boot from outer CV joint hous-
ing and slide it down interconnecting shaft.
(5) Wipe away grease to expose outer CV joint to
interconnecting shaft retaining ring.
(6) Spread ears apart on CV joint assembly to
interconnecting shaft retaining ring (Fig. 31).
(7) Slide outer CV joint assembly off end of inter-
connecting shaft.
(8) Slide sealing boot off interconnecting shaft.
(9) Thoroughly clean and inspect outer CV joint
assembly and interconnecting joint for any signs of
excessive wear.If any parts show signs of exces-
sive wear, the half shaft assembly will require
replacement. Component parts of these half
shaft assemblies are not serviceable.
INSTALLATION
(1) Slide the new small diameter seal boot retain-
ing clamp onto the interconnecting shaft. Then slide
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. 32). 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 housing. 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
Fig. 30 Outer CV Joint Seal Boot Clamps
1 - SMALL CLAMP
2 - SEALING BOOT
3 - OUTER C/V JOINT HOUSING
4 - LARGE CLAMP
5 - INTERCONNECTING SHAFT
Fig. 31 Outer CV Joint Removal From
Interconnecting Shaft
1 - SPREAD RETAINING RING EARS AND PULL JOINT OFF
SHAFT
2 - RETAINING RING
3 - RETAINING RING
4 - OUTER CV JOINT ASSEMBLY
5 - INTERCONNECTING SHAFT
Fig. 32 Outer CV Joint Installed On Interconnecting
Shaft
1 - INTERCONNECTING SHAFT
2 - RETAINING RING
3 - OUTER CV JOINT ASSEMBLY
3 - 12 HALF SHAFT - FRONTRS
CV BOOT - OUTER (Continued)

the thinnest (sight) groove on interconnecting
shaft is visible (Fig. 33).
(5) Place crimping tool C-4975-A over bridge of
clamp (Fig. 34).
(6) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 35).
CAUTION: Seal must not be dimpled, stretched, or
out-of-shape in any way. If seal is NOT shaped cor-
rectly, 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. 36).
(10) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 37).
Fig. 33 Seal Boot Correctly Positioned On
Interconnecting Shaft
1 - SEALING BOOT
2 - INTERCONNECTING SHAFT THINNEST GROOVE
3 - INTERCONNECTING SHAFT
4 - BOOT CLAMP
Fig. 34 Crimping Tool Installed on Sealing Boot Clamp
1 - SPECIAL TOOL C-4975A
2 - INTERCONNECTING SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 35 Sealing Boot Retaining Clamp Installed
1 - CLAMP
2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 - INTERCONNECTING SHAFT
4 - SEALING BOOT
Fig. 36 Crimping Tool Installed on Sealing Boot
Clamp - Typical
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975A
4 - SEALING BOOT
RSHALF SHAFT - FRONT3-13
CV BOOT - OUTER (Continued)