2001 DODGE TOWN AND COUNTRY boot

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)
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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. 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)
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(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)
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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)
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(11) Install the half shaft requiring boot replace-
ment back on the vehicle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT -
INSTALLATION)
OUTER CV JOINT BEARING
SHIELD
REMOVAL
(1) Clamp half shaft in a vise by the interconnect-
ing shaft.
(2) Using a drift (Fig. 38) 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. 39).
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.
Fig. 37 Sealing Boot Retaining Clamp Installed -
Typical
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. 38 Removing Bearing Shield from Outer CV
Joint
1 - DRIFT
2 - OUTER CV JOINT
3 - BEARING SHIELD
Fig. 39 Special Tools for Installing Bearing Shield
1 - SPECIAL TOOL C-4698-2
2 - SPECIAL TOOL C-4698-1
3 - BEARING SHIELD
4 - OUTER CV JOINT
3 - 14 HALF SHAFT - FRONTRS
CV BOOT - OUTER (Continued)
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HALF SHAFT - REAR
TABLE OF CONTENTS
page page
HALF SHAFT - REAR
DESCRIPTION...........................16
DIAGNOSIS AND TESTING.................16
HALF SHAFT..........................16
REMOVAL..............................16INSTALLATION...........................17
SPECIFICATIONS........................18
CV BOOT - INNER/OUTER
REMOVAL..............................18
INSTALLATION...........................20
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.
(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.
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 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).
3 - 16 HALF SHAFT - REARRS
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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 -
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).
(6) Remove the snap-ring holding the tripod
assembly onto the interconnecting shaft (Fig. 11).
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 - WAVE WASHER
Fig. 7 Clamp Shaft In Soft Jawed Vice
1 - HALF SHAFT BOOT
2 - HALF SHAFT
3 - VISE
3 - 18 HALF SHAFT - REARRS
HALF SHAFT - REAR (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).
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
RSHALF SHAFT - REAR3-19
CV BOOT - INNER/OUTER (Continued)
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