2001 CHRYSLER VOYAGER Service Manual

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Page 1593 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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).
INST

Page 1594 of 4284

CHRYSLER VOYAGER 2001 Service Manual SPECIFICATIONS
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 -

Page 1595 of 4284

CHRYSLER VOYAGER 2001 Service Manual (7) Remove the tripod assembly from the intercon-
necting shaft (Fig. 12).
(8) Remove the CV boot from the interconnecting
shaft (Fig. 13).
Fig. 8 Remove Boot Clamps
1 - HALF SHAFT BOOT
2 - CLAMP
Fig.

Page 1596 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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

Page 1597 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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-497

Page 1598 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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

Page 1599 of 4284

Page 1600 of 4284

CHRYSLER VOYAGER 2001 Service Manual PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DESCRIPTION...........................24
OPERATION.............................24REMOVAL..............................24
INSTALLATION.......

PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DESCRIPTION...........................24
OPERATION.............................24REMOVAL..............................24
INSTALLATION...........................24
SPECIFICATIONS........................25
PROPELLER SHAFT
DESCRIPTION
WARNING: Due to propeller shaft imbalance con-
cerns, the propeller shaft can only be serviced as
an assembly.
AWD models utilize a ªtwo-pieceº propeller shaft
(Fig. 1) to transmit power to the rear driveline mod-
ule assembly. This two-piece design consists of:
²Front and rear shaft segments.
²Plunging center CV joint
²Center support bearing
²Rubber coupler at driveline module flange
The front shaft segment utilizes a CV joint at the
power transfer unit connection, and a plunging CV
joint at the center bearing location.
The rear shaft segment utilizes a center support
bearing at the forward position, and a rubber coupler
at the driveline module flange.
OPERATION
The propeller shaft (Fig. 1) is used to transmit
torque from the transaxle power transfer unit (PTU)
to the rear driveline module of AWD equipped mod-
els.
The propeller shaft front half utilizes a CV joint at
the PTU flange, and a plunging CV joint at the cen-
ter bearing location. These joints are flexible, allow-
ing for torsional movement of the powertrain.
The propeller shaft rear half utilizes a center sup-
port bearing, which supports this two-piece assembly.
The bearing also stabilizes the rear shaft segment to
minimize axle wind-up. The rubber coupler at the
driveline module flange dampens out propeller shaft
torsional vibrations, as the driveline module it con-
nects to is fastened to the vehicle body.
REMOVAL
CAUTION: Propeller shaft removal is a two-man
operation. Never allow propeller shaft to hang whileconnected to power transfer unit (PTU) or rear driv-
eline module flanges. A helper is required.
(1) Make sure transaxle is in neutral (N). Using
chalk, mark propeller shaft flanges at PTU and rear
driveline module for installation reference.
(2) Remove six propeller shaft-to-power transfer
unit bolts.
(3) Have helper remove three propeller shaft rub-
ber coupler-to-driveline module bolts while he/she
supports rear shaft by hand.
(4) Remove center bearing support-to-crossmember
bolts, while supporting front shaft with two hands.
(5) Lower propeller shaft assembly to ground,
using care not to damage fore and aft flanges (Fig.
1).
INSTALLATION
CAUTION: Propeller shaft installation is a two-man
operation. Never allow propeller shaft to hang while
connected to power transfer unit (PTU) or rear driv-
eline module flanges. A helper is required.
(1) Make sure transaxle is in Neutral (N) position.
(2) Obtain a helper and lift propeller shaft assem-
bly into position (Fig. 1).
(3) While helper supports front half of shaft level
to underbody, align paint marks at driveline module
flange and install three propeller shaft rubber cou-
pler-to-rear driveline module bolts by hand. Do not
torque at this time.
(4) While helper supports front half of shaft level
to underbody, align chalk marks at PTU flange.
Install six propeller shaft-to-PTU flange bolts and
torque to 30 N´m (22 ft. lbs.). Torque bolts alternately
to ensure proper flange mating.
(5) Place center bearing into position. Install and
torque center bearing-to-crossmember bolts to 54
N´m (40 ft. lbs.).
(6) Torque propeller shaft rubber coupler-to-rear
driveline module assembly to 54 N´m (40 ft. lbs.).
3 - 24 PROPELLER SHAFTRS

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