Chrysler Town, Dodge Caravan. Manual — part 26
SHUDDER OR VIBRATION DURING ACCELERATION
This problem could be a result of:
• A worn or damaged half shaft inner tripod joint.
• A sticking tripod joint spider assembly (inner tri-
pod joint only).
• Improper wheel alignment. (Refer to 2 - SUS-
PENSION/WHEEL
ALIGNMENT
-
STANDARD
PROCEDURE)
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of:
• Foreign material (mud, etc.) packed on the back-
side of the wheel(s).
• Out of balance tires or wheels. (Refer to 22 -
TIRES/WHEELS - STANDARD PROCEDURE)
• Improper 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.
(3) Remove the wheel and tire assembly from the
vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL)
(4) Remove the wave washer (Fig. 3) from the end
of the half shaft.
(5) With the vehicle’s brakes applied to keep hub
from turning, loosen and remove the half shaft
nut.
(6) Remove
the
two
front
disc
brake
caliper
adapter to steering knuckle attaching bolts (Fig. 4).
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 - FRONT
RS
HALF SHAFT - FRONT (Continued)
(7) Remove the disc brake caliper assembly from
the steering knuckle. Caliper assembly is removed by
first rotating top of caliper assembly away from
steering knuckle and then removing bottom of assem-
bly out from under machined abutment on steering
knuckle.
(8) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 5). Do not allow the brake caliper assembly
to hang by the brake flex hose.
(9) Remove the brake rotor from the hub and bear-
ing assembly.
(10) Remove the steering knuckle-to-strut attach-
ment bolts (Fig. 6) from the steering knuckle.
(11) Pull the steering knuckle from the strut clevis
bracket.
NOTE: Care must be taken not to separate the inner
C/V joint during this operation. Do not allow half
shaft to hang by inner C/V joint after removing
outer C/V Joint from the hub/bearing assembly in
steering knuckle, end of half shaft must be sup-
ported.
Fig. 3 Wave Washer
1 - HUB/BEARING ASSEMBLY
2 - WAVE WASHER
3 - STUB AXLE
Fig. 4 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 5 Properly Supported Disc Brake Caliper -
Typical
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
Fig. 6 Strut To Steering Knuckle Attaching Bolts
1 - STRUT CLEVIS BRACKET
2 - NUTS AND BOLTS
3 - STEERING KNUCKLE
RS
HALF SHAFT - FRONT
3 - 3
HALF SHAFT - FRONT (Continued)
(12) Pull steering knuckle assembly down and
away from the outer C/V joint of the half shaft
assembly while pulling the joint out of the hub bear-
ing.
(13) Support the outer end of the half shaft assem-
bly. Insert a pry bar between inner tripod joint and
transaxle case (Fig. 7). Pry against inner tripod joint,
until tripod joint retaining snap-ring is disengaged
from transaxle side gear.
(14) Hold inner tripod joint and interconnecting
shaft of half shaft assembly. Remove inner tripod
joint from transaxle, by pulling it straight out of
transaxle side gear and transaxle oil seal (Fig. 8).
When removing tripod joint, do not let spline or
snap-ring drag across sealing lip of the trans-
axle to tripod joint oil seal.
INSTALLATION
(1) Thoroughly clean spline and oil seal sealing
surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans-
mission lubricant.
(2) Holding half shaft assembly by tripod joint and
interconnecting shaft, install tripod joint into trans-
axle side gear as far as possible by hand (Fig. 8).
(3) Grasp inner tripod joint an interconnecting
shaft. Forcefully push the tripod joint into side gear
of transaxle, until snap-ring is engaged with trans-
axle
side
gear.
Test
that
snap-ring
is
fully
engaged
with
side
gear
by
attempting
to
remove tripod joint from transaxle by hand. If
snap-ring is fully engaged with side gear, tripod
joint will not be removable by hand.
(4) Clean all debris and moisture out of steering
knuckle, in the area were outer CV joint will be
installed into steering knuckle.
(5) Ensure that front of outer CV joint which fits
against the face of the hub and bearing is free of
debris and moisture before installing outer CV joint
into hub and bearing assembly (Fig. 9).
(6) Slide half shaft back into front hub and bear-
ing assembly.
Fig. 7 Disengaging Inner Tripod Joint From
Transaxle
1 - INNER TRIPOD JOINT
2 - TRANSAXLE CASE
3 - PRY BAR
Fig. 8 Tripod Joint Removal from Transaxle
1 - INNER TRIPOD JOINT
2 - TRANSAXLE
3 - SPLINE
4 - OIL SEAL
5 - SNAP-RING
6 - INTERCONNECTING SHAFT
Fig. 9 Outer CV Joint Inspection
1 - OUTER C/V JOINT
2 - THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL
DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
STEERING KNUCKLE.
3 - 4
HALF SHAFT - FRONT
RS
HALF SHAFT - FRONT (Continued)
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckle.
CAUTION: If the vehicle being serviced is equipped
with eccentric strut assembly attaching bolts, the
eccentric bolt must be installed in the bottom (slot-
ted) hole on the strut clevis bracket (Fig. 10).
(7) Install steering knuckle in clevis bracket of
strut damper assembly. Install the strut damper to
steering knuckle attaching bolts. Tighten both bolts
to a torque of 81 N·m (60 ft. lbs.) plus an additional
1/4 turn.
(8) Install braking disc on hub and bearing assem-
bly.
(9) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding bottom of
caliper
assembly
under
abutment
on
steering
knuckle, and then rotating top of caliper against top
abutment.
(10) Install disc brake caliper adapter to steering
knuckle attaching bolts (Fig. 4). Tighten the disc
brake caliper adapter attaching bolts to a torque of
169 N·m (125 ft. lbs.).
(11) Clean all foreign matter from the threads of
the outer CV joint. Install the washer and half shaft
to hub/bearing assembly nut on half shaft and
securely tighten nut.
(12) Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half the
required specification. Then repeat the tightening
sequence to the full specified torque of 135 N·m (100
ft. lbs.).
(13) Lower vehicle.
(14) With the vehicle’s brakes applied to keep hub
from turning, tighten the hub nut to a torque of 244
N·m (180 ft. lbs.) (Fig. 11).
(15) Install the spring wave washer on the end of
the half shaft.
(16) Install the hub nut lock, and a new cotter pin
(Fig. 2). Wrap cotter pin prongs tightly around the
hub nut lock as shown in (Fig. 2).
(17) Check for correct fluid level in transaxle
assembly. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 10 Correctly Installed Eccentric Attaching Bolt
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
Fig. 11 Torquing Front Half Shaft To Hub Nut
1 - TORQUE WRENCH
RS
HALF SHAFT - FRONT
3 - 5
HALF SHAFT - FRONT (Continued)
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