boot CHRYSLER VOYAGER 2002 Service Manual

SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION.....................1
REAR SUSPENSION......................26WHEEL ALIGNMENT.....................46
FRONT SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION.......2
OPERATION - FRONT SUSPENSION.........2
STANDARD PROCEDURE - LUBRICATION....2
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE . . 3
SPECIAL TOOLS
FRONT SUSPENSION...................3
BUSHINGS
REMOVAL - STABILIZER BAR CUSHION......4
INSTALLATION - STABILIZER BAR CUSHION . . . 4
HUB / BEARING
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - HUB AND
BEARING............................5
REMOVAL.............................5
INSTALLATION..........................6
KNUCKLE
DESCRIPTION..........................6
OPERATION............................6
REMOVAL - STEERING KNUCKLE...........7
INSPECTION - STEERING KNUCKLE.........8
INSTALLATION - STEERING KNUCKLE.......9
LOWER BALL JOINT
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING - LOWER BALL
JOINT..............................10
LOWER BALL JOINT SEAL BOOT
DESCRIPTION - EXPORT.................10
REMOVAL
REMOVAL - BALL JOINT SEAL BOOT......11
REMOVAL - EXPORT...................11INSTALLATION
INSTALLATION - BALL JOINT SEAL BOOT . . 11
INSTALLATION - EXPORT...............12
LOWER CONTROL ARM
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL - LOWER CONTROL ARM........12
DISASSEMBLY
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - STANDARD)..........13
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO).............13
INSPECTION - LOWER CONTROL ARM......14
ASSEMBLY
ASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - STANDARD)..........14
ASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO).............15
INSTALLATION - LOWER CONTROL ARM....15
STABILIZER BAR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................17
INSPECTION..........................17
INSTALLATION.........................18
STRUT
DESCRIPTION - STRUT ASSEMBLY.........19
OPERATION - STRUT ASSEMBLY..........19
DIAGNOSIS AND TESTING - STRUT
ASSEMBLY..........................20
REMOVAL - STRUT ASSEMBLY............20
DISASSEMBLY - STRUT ASSEMBLY........22
ASSEMBLY - STRUT ASSEMBLY...........23
INSTALLATION - STRUT ASSEMBLY........25
RSSUSPENSION2-1
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(7) If equipped with antilock brakes, install wheel
speed sensor and mounting bolt on steering knuckle
(Fig. 13). Tighten the speed sensor bolt to a torque of
7 N´m (60 in. lbs.).
(8) Install brake rotor on hub and bearing (Fig. 9).
(9) Install disc brake caliper and adapter assembly
on steering knuckle. Install adapter amounting bolts
and tighten to 169 N´m (125 ft. lbs.).
(10) Clean any debris from the threads of the
outer C/V joint stub axle.
(11) Install the washer and hub nut on stub axle.
(12) Have a helper apply the vehicle's brakes to
keep hub from turning, then tighten hub nut to a
torque of 244 N´m (180 ft. lbs.).
(13) Install the spring wave washer on the end of
the stub axle.
(14) Install the hub nut lock, and anewcotter pin
(Fig. 8). Wrap cotter pin prongs tightly around the
hub nut lock.
(15) Install wheel and tire assembly. Install and
tighten the wheel mounting nuts in proper sequence
until all nuts are torqued to half the required speci-
fication. Then repeat the tightening sequence to the
full specified torque of 135 N´m (100 ft. lbs.).
(16) Lower vehicle.
(17) Set front wheel alignment camber and toe as
necessary. (Refer to 2 - SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE)
LOWER BALL JOINT
DESCRIPTION
The ball joint is an integral part of the lower con-
trol arm (Fig. 1). The ball joint has a tapered stud
that is pressed into the aluminum knuckle. The ball
joint stud is threaded on the end for a retainer nut.
The ball joint has a non-vented seal boot. The seal
boot has an integrated heat shield.
The ball joint used in the lower control arm of this
vehicle is a sealed-for-life ball joint and requires no
maintenance lubrication. The ball joint has been
lubricated-for-life during the manufacturing process.
A special fitting cap is installed on the fill port. This
cap must not be removed and replaced with a com-
mon zirc fitting. The special cap is there to eliminate
the possibility of lubrication latter during the ball
joints life, thus damaging the non-vented seal boot.
NOTE: The ball joint does not require any type of
additional lubrication for the life of the vehicle. No
attempt should be made to ever add any lubrication
to the lower ball joint.
OPERATION
The ball joint is a pivotal joint on the lower control
arm that allows the knuckle to move up and down,
and turn with ease.
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
With the weight of the vehicle resting on the road
wheels, grasp the special fitting cap on the bottom of
the ball joint and with no mechanical assistance or
added force, attempt to rotate the grease fitting.
If the ball joint is worn, the grease fitting will
rotate easily. If movement is noted, replacement of
the control arm is recommended.
LOWER BALL JOINT SEAL
BOOT
DESCRIPTION - EXPORT
The lower ball joint seal boot is a two piece unit. It
consists of the seal boot, plus a separate shield that
is located in a groove at the top of the seal boot.
NOTE: The seal boot should only be replaced if
damaged during vehicle service. The entire lower
control arm should be replaced if the joint has been
contaminated.
Fig. 16 Correctly Installed Eccentric Attaching Bolt
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
2 - 10 FRONT SUSPENSIONRS
KNUCKLE (Continued)
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REMOVAL
REMOVAL - BALL JOINT SEAL BOOT
(1) Remove steering knuckle from vehicle. (Refer
to 2 - SUSPENSION/FRONT/KNUCKLE -
REMOVAL)
(2) Using a screw driver or other suitable tool, pry
the seal boot off of the ball joint (Fig. 17)
(3) Inspect the ball joint for evidence of dirt or
water intrusion and wipe clean as necessary. If dirt
or water intrusion is extreme and joint cannot be
properly cleaned, the lower control arm will need to
be replaced. (Refer to 2 - SUSPENSION/FRONT/
LOWER CONTROL ARM - REMOVAL)
REMOVAL - EXPORT
(1) Remove steering knuckle from vehicle. (Refer
to 2 - SUSPENSION/FRONT/KNUCKLE -
REMOVAL)
(2) Remove shield from seal boot by gently pulling
on it.
(3) Using a screw driver or other suitable tool, pry
seal boot off lower ball joint.
INSTALLATION
INSTALLATION - BALL JOINT SEAL BOOT
(1) Place a liberal dab of MopartWheel Bearing
Grease around the base of the ball joint stem at the
socket.
(2) Install aNEWseal boot by hand as far as pos-
sible on the ball joint. Installation of the seal boot is
to be with the shield positioned as shown (Fig. 18).CAUTION: Do not use an arbor press to install the
sealing boot on the ball joint. Damage to the seal-
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
(3) Place Installer, Special Tool 6758, over seal
boot and squarely align it with bottom edge of seal
boot (Fig. 19). Apply hand pressure (or gently tap
with a hammer) to Special Tool 6758 until seal boot
is pressed squarely against top surface of lower con-
trol arm.
Fig. 17 Ball Joint Seal Boot Removal (Typical)
1 - LOWER CONTROL ARM
2 - BALL JOINT STUD
3 - SEAL BOOT
4 - SCREW DRIVER
5 - BALL JOINT ASSEMBLY
Fig. 18 Ball Joint Seal Boot Installed Position
(Typical)
1 - BALL JOINT SEAL BOOT
2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
4 - SHIELD
Fig. 19 Installing Ball Joint Seal Boot
1 - SHIELD
2 - SPECIAL TOOL 6758
3 - LOWER CONTROL ARM
4 - BALL JOINT SEAL BOOT
RSFRONT SUSPENSION2-11
LOWER BALL JOINT SEAL BOOT (Continued)
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(4) Wipe any grease off the ball joint stem using a
clean shop towel with MopartBrake Parts Cleaner
applied to it.
CAUTION: Do not attempt to install a normal grease
zirc in the ball joint an lubricate the joint through
the zirc fitting.
(5) Reinstall steering knuckle on vehicle. (Refer to
2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
INSTALLATION - EXPORT
(1) Place a liberal dab of MopartWheel Bearing
Grease around the base of the ball joint stem at the
socket.
(2) Install aNEWseal boot by hand as far as pos-
sible on the ball joint.
CAUTION: Do not use an arbor press to install the
sealing boot on the ball joint. Damage to the seal-
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
(3) Place Installer, Special Tool 6758, over seal
boot and squarely align it with bottom edge of seal
boot (Fig. 20). Apply hand pressure to Special Tool
6758 until seal boot is pressed squarely against top
surface of lower control arm.
(4) Wipe any grease off the ball joint stem.
(5) Place the shield over the top of the seal boot
and stretch it into the groove at the top of the seal
boot.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)
LOWER CONTROL ARM
DESCRIPTION
The lower control arm is mounted to the front sus-
pension crossmember using a pivot bolt through the
center of the front pivot bushing, and the front sus-
pension cradle crossmember reinforcement traps the
rear bushing in the crossmember (Fig. 1).
The lower control arm is an iron casting with two
rubber bushings and a ball joint. The lower control
arm front bushing is the spool type and is pressed
into the lower control arm. The standard (Low-line)
lower control arm rear bushing is a push-on bushing
that is pushed over a stem on the rear of the lower
control arm. The optional (High-line, Premium,
Sport) lower control arm rear bushing is a hydro-
bushing that is pressed on. It has liquid filled voids
that provide more effective dampening than the stan-
dard bushing. Vehicles with rear hydro-bushings uti-
lize a different lower control arm than vehicles with
standard bushings. They have a straight slightly
tapered round stem where the hydro-bushing is
mounted whereas the standard arm has a straight
stem with a squared knob on the end to retain the
bushing.
The lower control arm ball joint is pressed into the
outer end of the arm. The ball joint has a tapered
stud and retainer nut for fastening it to the steering
knuckle.
OPERATION
The lower control arm supports the lower end of
the steering knuckle and allows for the up and down
movement of the suspension during the jounce and
rebound travel. The lower control arm ball joint con-
nects the arm to the steering knuckle.
REMOVAL - LOWER CONTROL ARM
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel and tire assembly.
(3) Remove the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(4) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 21).
Fig. 20 Installing Ball Joint Seal Boot (Typical)
1 - SHIELD (NOT ON RG VEHICLE)
2 - SPECIAL TOOL 6758
3 - LOWER CONTROL ARM
4 - BALL JOINT SEAL BOOT
2 - 12 FRONT SUSPENSIONRS
LOWER BALL JOINT SEAL BOOT (Continued)
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The coil spring controls ride quality and maintains
proper ride height.
The spring isolators isolate the coil spring at the
top and bottom from coming into metal-to-metal con-
tact with the upper seat and strut.
The jounce bumper limits suspension travel and
metal-to-metal contact under full jounce condition.
The strut dampens jounce and rebound motions of
the coil spring and suspension.
During steering maneuvers, the strut assembly
(through a pivot bearing in the upper strut mount)
and steering knuckle (through the lower ball joint)
turn as an assembly.
DIAGNOSIS AND TESTING - STRUT ASSEMBLY
(1) Inspect for damaged or broken coil springs
(Fig. 38).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 38).
(3) Inspect the coil spring isolator on the lower
spring seat for any signs of damage or deterioration.
(4) Lift dust boot (Fig. 39) and inspect strut
assembly for evidence of fluid running from the
upper end of fluid reservoir. (Actual leakage will be astream of fluid running down the side and dripping
off lower end of unit). A slight amount of seepage
between the strut rod and strut shaft seal is not
unusual and does not affect performance of the strut
assembly (Fig. 39). Also inspect jounce bumpers for
signs of damage or deterioration.
REMOVAL - STRUT ASSEMBLY
WARNING: DO NOT REMOVE THE NUT FROM THE
STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT
ASSEMBLY SPRING IS COMPRESSED.
(1) Raise the vehicle. See Hoisting in Lubrication
and Maintenance.
(2) Remove the wheel and tire assembly from loca-
tion on front of vehicle requiring strut removal.
(3) If both strut assemblies are to be removed,
mark the strut assemblies right or left according to
which side of the vehicle they were removed from.
(4) Remove the hydraulic brake hose routing
bracket and the speed sensor cable routing bracket
from the strut damper brackets (Fig. 40).
Fig. 38 STRUT ASSEMBLY
1 - NUT 6 - COIL SPRING
2 - UPPER MOUNT 7 - DUST SHIELD
3 - PIVOT BEARING 8 - JOUNCE BUMPER
4 - UPPER SPRING SEAT 9 - LOWER SPRING ISOLATOR
5 - UPPER SPRING ISOLATOR 10 - STRUT (DAMPER)
2 - 20 FRONT SUSPENSIONRS
STRUT (Continued)
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CAUTION: When removing the nut from the stud of
the stabilizer bar link, do not allow the stud to
rotate in it's socket. Hold the stud from rotating by
placing an open-end wrench on the flat machined
into the stud (Fig. 41).
(5) Remove the stabilizer bar link from the bracket
on the strut assembly (Fig. 41). To do so, place anopen-end wrench on the flat machined into the link's
mounting stud, then remove the nut while holding
the wrench in place. Push the stud out of the
bracket.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(6) Remove the 2 strut assembly clevis bracket to
steering knuckle attaching bolts (Fig. 42).
Fig. 39 Strut Assembly Leakage Inspection (Typical)
1 - DUST BOOT
2 - STRUT SHAFT
3 - STRUT FLUID RESERVOIR
4 - INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID
LEAKAGE
Fig. 40 Brake Hose And Speed Sensor Cable
Routing
1 - STRUT DAMPER
2 - WHEEL SPEED SENSOR CABLE
3 - ROUTING BRACKET
4 - HYDRAULIC BRAKE HOSE
5 - ATTACHING BOLT
6 - ROUTING BRACKET
Fig. 41 Stabilizer Bar Link To Strut Attachment
1 - NUT
2 - STRUT
3 - STABILIZER BAR LINK
Fig. 42 Strut Damper Attachment To Steering
Knuckle
1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
5 - STEERING KNUCKLE
RSFRONT SUSPENSION2-21
STRUT (Continued)
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(11) Remove the jounce bumper from the dust
shield. The jounce bumper is removed from the dust
shield by collapsing the dust shield until the jounce
bumper can be pulled free from the dust boot.
(12) Remove the spring isolator from the lower
spring seat on the strut (Fig. 38).
(13) Inspect the strut assembly components (Fig.
38) for the following and replace as necessary:
²Inspect the strut for any condition of shaft bind-
ing over the full stroke of the shaft.
²Check the upper mount for cracks and distortion
and its retaining studs for any sign of damage.
²Check the upper seat for stress cracks and wear.
²Check the upper spring isolator for severe dete-
rioration.
²Check for binding of the strut assembly pivot
bearing.
²Inspect the dust shield for rips and deteriora-
tion.
²Inspect the jounce bumper for cracks and signs
of deterioration.
ASSEMBLY - STRUT ASSEMBLY
For the disassembly and assembly of the strut
assembly, use of Strut Spring Compressor, Pentastar
Service Equipment (PSE) tool W-7200, or the equiva-
lent, is recommended to compress the coil spring.
Follow the manufacturer's instructions closely.NOTE: Coil Springs on this vehicle are side-ori-
ented. Springs on the left side of the vehicle have a
left-hand wind top-to-bottom while springs on the
right side have a right-hand wind top-to-bottom.
Left and right springs must not be interchanged.
NOTE: If the coil spring has been removed from the
spring compressor, proceed with the next step, oth-
erwise, proceed with step 5.
(1) Place the coil spring in the compressor lower
hooks following the manufacturers instructions.
Proper orientation of the spring to the strut (once
installed) is necessary. Consider the following when
placing the coil spring in the compressor: From
above, the compressor back is at the 12 o'clock posi-
tion, and you, standing in the front of the machine,
are at the 6 o'clock position. Place the lower coil
spring end at the 6 o'clock position for both left and
right springs. (Fig. 46).
(2) Install the upper seat and upper isolator on top
of the coil spring. Position the notch in the perimeter
of the upper seat toward the front of the compressor
(same 6 o'clock position as in step 1).
(3) Position the upper hooks on top of the coil
spring upper seat so the upper hooks span approxi-
mately 1 inch past outside diameter of upper seat
(Fig. 47). This will allow proper clearance for upper
mount installation without pinching the hooks in-be-
tween the two pieces.Do not allow hooks to be
placed closer to edge.
(4) Compress the coil spring far enough to allow
strut installation.
Fig. 45 Retaining Nut Removal/Installation (Typical)
1 - UPPER MOUNT
2 - SPECIAL TOOL 6864
Fig. 46 Spring Positioned In Compressor (Right
Spring Shown)
1 - COMPRESSOR LOWER HOOKS
2 - COIL SPRING END
RSFRONT SUSPENSION2-23
STRUT (Continued)
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(5) If the pivot bearing has been removed from the
upper seat, install the pivot bearing on the top of the
upper spring seat (Fig. 48). The bearing must be
installed on upper seat with the smaller diameter
side of the pivot bearing toward the spring seat. Be
sure the pivot bearing is sitting flat on the spring
seat once mounted.
(6) Install the spring isolator on the lower spring
seat of the strut (Fig. 38).
(7) Install the jounce bumper on the strut shaft
(Fig. 38). The jounce bumper is to be installed with
the small end pointing downward.
(8) Install the dust shield on the strut. Collapse
and stretch the dust shield down over the top of the
jounce bumper until the dust shield snaps into theslot on the jounce bumper. The jounce bumper will be
at the top of the inner dust boot. Return the dust
shield to its fully extended length.
(9) Install the strut through the bottom of the coil
spring until the lower spring seat contacts the lower
end of the coil spring. The clevis bracket on the strut
should point straight outward away from the com-
pressor (to the 6 o'clock position). This position
should be within 5É of the lower end tip of the coil
spring (Fig. 49). If necessary, reposition the strut or
coil spring in the compressor so both of these line up
straight outward away from the compressor (to the 6
o'clock position). Install the clamp to hold the strut
and coil together.
(10) Install the strut mount over the strut shaft
and onto the top of the pivot bearing and upper seat
as shown (Fig. 44). Loosely install the retaining nut
on the strut shaft.
(11) Install Strut Nut Socket (on the end of a
torque wrench), Special Tool 6864, on the strut shaft
retaining nut (Fig. 45). Next, install a 10 mm socket
on the hex on the end of the strut shaft. While hold-
ing the strut shaft from turning, tighten the strut
shaft retaining nut to a torque of 100 N´m (75 ft.
lbs.).
NOTE: Before releasing the tension the compressor
has on the spring, using the following figure as ref-
erence (Fig. 50), make sure the upper spring seat,
coil spring and strut clevis bracket are all lined up
properly (within 5É of one another).
Fig. 47 Hook Placement On Upper Seat
1 - HOOKS POSITIONED 1 INCH FROM EDGE
2 - PIVOT BEARING AND UPPER SEAT
Fig. 48 Pivot Bearing Installation
1 - PIVOT BEARING
2 - UPPER SEAT
Fig. 49 Coil Spring Positioning
1 - FRONT OF VEHICLE
2 - END OF RIGHT COIL SPRING AT STRUT LOWER SEAT
3 - LOWER SEATS OF STRUTS
4 - STRUT CLEVIS BRACKETS
5 - END OF LEFT COIL SPRING AT STRUT LOWER SEAT
2 - 24 FRONT SUSPENSIONRS
STRUT (Continued)
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CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.
(2) Loosen front inner to outer tie rod end jam
nuts (Fig. 12). Grasp inner tie rods at serrations and
rotate inner tie rods of steering gear (Fig. 12) to set
front toe to the preferred toe specification. (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - SPECIFI-
CATIONS)
(3) Tighten tie rod jam nuts (Fig. 12) to 75 N´m
(55 ft. lbs.) torque.
(4) Adjust steering gear to tie rod boots at the
inner tie rod.
(5) Remove steering wheel clamp.
(6) Remove the alignment equipment.
(7) Road test the vehicle to verify the steering
wheel is straight and the vehicle does not wander or
pull.
STANDARD PROCEDURE - CURB HEIGHT
MEASUREMENT
The wheel alignment is to be checked and all align-
ment adjustments made with the vehicle at its
required curb height specification.
Vehicle height is to be checked with the vehicle on
a flat, level surface, preferably a vehicle alignmentrack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as stan-
dard equipment. Vehicle height is checked with the
fuel tank full of fuel, and no passenger or luggage
compartment load.
Vehicle height is not adjustable. If the measure-
ment is not within specifications, inspect the vehicle
for bent or weak suspension components. Compare
the parts tag on the suspect coil spring(s) to the
parts book and the vehicle sales code, checking for a
match. Once removed from the vehicle, compare the
coil spring height to a correct new or known good coil
spring. The heights should vary if the suspect spring
is weak.
(1) Measure from the inboard edge of the wheel
opening fender lip directly above the wheel center
(spindle), to the floor or alignment rack surface.
(2) When measuring, the maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).
(3) Compare the measurements to the specifica-
tions listed in the following Curb Height Specifica-
tions charts.
Fig. 11 Camber Adjustment Cam Bolt
1 - STEERING KNUCKLE
2 - CLEVIS BRACKET CAM STOP AREAS
3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT
Fig. 12 Front Wheel Toe Adjustment
1 - INNER TIE ROD SERRATION
2 - OUTER TIE ROD JAM NUT
3 - OUTER TIE ROD END
4 - INNER TIE ROD
5 - STEERING KNUCKLE
2 - 54 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)
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DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT.....................1
HALF SHAFT - REAR.....................14PROPELLER SHAFT.....................22
REAR DRIVELINE MODULE................24
HALF SHAFT - FRONT
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT
DESCRIPTION..........................1
DIAGNOSIS AND TESTING - HALF SHAFT.....1
REMOVAL.............................2
INSTALLATION..........................4
SPECIFICATIONS - HALF SHAFT - FRONT....6
CV BOOT - INNER
REMOVAL.............................6INSTALLATION..........................6
CV BOOT - OUTER
REMOVAL.............................10
INSTALLATION.........................10
OUTER CV JOINT BEARING SHIELD
REMOVAL.............................13
INSTALLATION.........................13
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 using
a snap ring located in the stub shaft of the tripod
joint. The outer CV joint has a stub shaft that issplined 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.
RSDIFFERENTIAL & DRIVELINE3-1
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