boot CHRYSLER VOYAGER 2003 Owner's Guide

(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 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
the thinnest (sight) groove on interconnecting
shaft is visible (Fig. 30).
(5) Place crimping tool C- 4975-A over bridge of
clamp (Fig. 31).
(6) Tighten nut on crimping tool C- 4975-A until
jaws on tool are closed completely together, face to
face (Fig. 32).
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
Fig. 31 Crimping Tool Installed on Sealing Boot
Clamp
1 - SPECIAL TOOL C-4975-A
2 - INTERCONNECTING SHAFT
3 - CLAMP
4 - SEALING BOOT
RSHALF SHAFT - FRONT3-11
CV BOOT - OUTER (Continued)
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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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HALF SHAFT - REAR
TABLE OF CONTENTS
page page
HALF SHAFT - REAR
DESCRIPTION.........................13
DIAGNOSIS AND TESTING - HALF SHAFT....13
REMOVAL.............................13
INSTALLATION.........................14SPECIFICATIONS - HALF SHAFT - FRONT . . . 15
CV BOOT - INNER/OUTER
REMOVAL.............................15
INSTALLATION.........................17
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)
REMOVAL
(1) Lift vehicle on hoist so that the wheels hang
freely.
(2) Remove rear wheel.
(3) Remove cotter pin, nut lock, and spring washer
(Fig. 1).
Fig. 1 Cotter Pin, Nut Lock, And Spring Washer
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
RSHALF SHAFT - REAR3-13
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(5) Install the spring 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
Flange61 45 -
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).
Fig. 6 Cotter Pin, Nut Lock, And Spring Washer
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
Fig. 7 Clamp Shaft In Soft Jawed Vice
1 - HALF SHAFT BOOT
2 - HALF SHAFT
3 - VISE
RSHALF SHAFT - REAR3-15
HALF SHAFT - REAR (Continued)
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(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).
(6) Remove the snap-ring holding the tripod
assembly onto the interconnecting shaft (Fig. 11).
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
Fig. 11 Remove Snap-Ring
1 - SNAP RING
2 - HALF SHAFT BOOT
3 - TRIPOD ASSEMBLY
4 - SNAP RING PLIERS
3 - 16 HALF SHAFT - REARRS
CV BOOT - INNER/OUTER (Continued)
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(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 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).
(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.
(10) Position the CV joint boot 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).
Fig. 12 Slide Tripod Off The Shaft
1 - TRIPOD ASSEMBLY
2 - AXLE SHAFT
3 - HALF SHAFT BOOT
Fig. 13 Remove Boot
1 - HALF SHAFT BOOT
Fig. 14 Install CV Boot Onto Interconnecting Shaft
1 - HALF SHAFT BOOT
RSHALF SHAFT - REAR3-17
CV BOOT - INNER/OUTER (Continued)
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(11) Install CV joint seal boot to interconnecting
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.
Fig. 15 Slide Tripod Onto The Interconnecting Shaft
1 - TRIPOD ASSEMBLY
2 - AXLE SHAFT
3 - HALF SHAFT BOOT
Fig. 16 Install Snap-Ring
1 - SNAP RING
2 - HALF SHAFT BOOT
3 - TRIPOD ASSEMBLY
4 - SNAP RING PLIERS
Fig. 17 Install CV Housing
1 - HALF SHAFT JOINT HOUSING
2 - BOOT
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
3 - 18 HALF SHAFT - REARRS
CV BOOT - INNER/OUTER (Continued)
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(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.
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. 21).
(2) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 22).
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
Fig. 21 Crimping Tool Installed on Sealing Boot
Clamp - Typical
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975-A
4 - SEALING BOOT
Fig. 22 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
RSHALF SHAFT - REAR3-19
CV BOOT - INNER/OUTER (Continued)
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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. 23).
(2) Squeeze tool together until top band of clamp is
latched behind the two tabs on lower band of clamp
(Fig. 24).
(16) Install the half shaft into the vehicle. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT
- INSTALLATION)
Fig. 23 Clamping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - TOOL YA3050, OR EQUIVALENT
3 - SEALING BOOT
Fig. 24 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
3 - 20 HALF SHAFT - REARRS
CV BOOT - INNER/OUTER (Continued)
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SPECIAL TOOLS
BASE BRAKE SYSTEM
BRAKE FLUID LEVEL SWITCH
DESCRIPTION
The brake fluid level switch is located in the brake
fluid reservoir of the master cylinder (Fig. 4).
OPERATION
The purpose of the brake fluid level switch is to
provide the driver with an early warning that the
brake fluid level in the master cylinder fluid reser-
voir has dropped below a normal level. This may
indicate:
²Abnormal loss of brake fluid in the master cyl-
inder fluid reservoir resulting from a leak in the
hydraulic system.
²Brake shoe linings which have worn to a point
requiring replacement.
As the brake fluid drops below the minimum level,
the brake fluid level switch closes to complete the red
BRAKE warning indicator (lamp) circuit. This will
turn on the red BRAKE warning indicator. The mas-
ter cylinder fluid reservoir should be checked and
refilled to the Full mark with DOT 3 brake fluid.If
the brake fluid level has dropped below the add
Tubes, Master Cylinder Bleeding 6920
Tubes, Master Cylinder Bleed 8358
Adapter, Master Cylinder Pressure Bleed Cap 6921
Dial Indicator, C-3339
Gauge, Brake Safe-Set
Handle, Universal C±4171
Installer, Dust Boot C-4689 or C-4842
5 - 10 BRAKES - BASERS
BRAKES - BASE (Continued)
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