2002 CHRYSLER CARAVAN boot

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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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.(2) Remove the cotter pin and nut lock (Fig. 2)
from the end of the half shaft.
Fig. 1 Unequal Length Half Shaft System
1 - STUB AXLE 8 - OUTER C/V JOINT
2 - OUTER C/V JOINT 9 - RIGHT HALFSHAFT
3 - OUTER C/V JOINT BOOT 10 - INNER TRIPOD JOINT BOOT
4 - TUNED RUBBER DAMPER WEIGHT 11 - INNER TRIPOD JOINT
5 - INTERCONNECTING SHAFT 12 - INNER TRIPOD JOINT
6 - OUTER C/V JOINT BOOT 13 - INNER TRIPOD JOINT BOOT
7 - STUB AXLE 14 - INTERCONNECTING SHAFT LEFT HALFSHAFT
Fig. 2 Half Shaft Retaining Nut
1 - HUB/BEARING
2 - NUT LOCK
3 - COTTER PIN
4 - STUB AXLE
3 - 2 HALF SHAFT - FRONTRS
HALF SHAFT - FRONT (Continued)
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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 tri-
pod joint sealing boot to tripod joint housing and discard.
(3)Remove small clamp which retains inner tripod
joint sealing boot to interconnecting shaft and discard.
(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. 12).(6) Remove snap-ring which retains spider assem-
bly to interconnecting shaft (Fig. 13).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. 14).
(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.
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
Fig. 12 Spider Assembly Removal from Tripod Joint
Housing
1 - TRIPOD JOINT HOUSING
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
Fig. 13 Spider Assembly Retaining Snap-Ring
1 - INTERCONNECTING SHAFT
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP-RING
3 - 6 HALF SHAFT - FRONTRS
HALF SHAFT - FRONT (Continued)
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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. 15).(2) Install spider assembly onto interconnecting
shaft (Fig. 16). 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. 17).Do not hit the outer tripod
bearings in an attempt to install spider assem-
bly on interconnecting shaft.
Fig. 14 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. 15 Sealing Boot Installation on Interconnecting
Shaft
1 - SEALING BOOT
2 - RAISED BEAD IN THIS AREA OF SEALING BOOT
3 - GROOVE
4 - INTERCONNECTING SHAFT
Fig. 16 Spider Assembly Installation on
Interconnecting Shaft
1 - SPIDER ASSEMBLY
2 - INTERCONNECTING SHAFT
Fig. 17 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
RSHALF SHAFT - FRONT3-7
CV BOOT - INNER (Continued)
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(3) Install the spider assembly to interconnecting
shaft retaining snap-ring into groove on end of inter-
connecting shaft (Fig. 18). Be sure the snap-ring is
fully seated into groove on interconnecting shaft.
(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. 19).(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. 20).
(8) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 21).
Fig. 18 Spider Assembly Retaining Snap-Ring
Installed
1 - INTERCONNECTING SHAFT
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP-RING
Fig. 19 Installing Tripod Housing on Spider
Assembly
1 - TRIPOD JOINT HOUSING
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
Fig. 20 Crimping Tool Installed on Sealing Boot
Clamp - Typical
1 - SPECIAL TOOL C-4975-A
2 - INTERCONNECTING SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 21 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
3 - 8 HALF SHAFT - FRONTRS
CV BOOT - INNER (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.
(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 deter-
mines 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 assembly,
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. 22).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 interconnect-
ing shaft so it is at the center of its travel in the tripodjoint housing. Remove the trim stick from between the
sealing boot insert and the CV joint housing.This proce-
dure 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. 23).
(2) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 24).
Fig. 22 Trim Stick Inserted for Venting CV Joint
1 - INNER CV JOINT SEALING BOOT
2 - SEALING BOOT CLAMP
3 - INNER CV JOINT HOUSING
4 - TRIM STICK
Fig. 23 Crimping Tool Installed on Sealing Boot Clamp
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975-A
4 - SEALING BOOT
Fig. 24 Sealing Boot Retaining Clamp Installed
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 - FRONT3-9
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. 25).
(2) Squeeze tool together until top band of clamp is
latched behind the two tabs on lower band of clamp
(Fig. 26).
(14) 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)
(2) Remove large boot clamp retaining CV joint
sealing boot to CV joint housing (Fig. 27) 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. 28).
(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
Fig. 25 Clamping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - TOOL YA3050, OR EQUIVALENT
3 - SEALING BOOT
Fig. 26 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
Fig. 27 Outer CV Joint Seal Boot Clamps
1 - SMALL CLAMP
2 - SEALING BOOT
3 - OUTER C/V JOINT HOUSING
4 - LARGE CLAMP
5 - INTERCONNECTING SHAFT
3 - 10 HALF SHAFT - FRONTRS
CV BOOT - INNER (Continued)
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