Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 60
(11) Tilt the cage and inner race assembly vertically
and position two opposing cage windows in area be-
tween the ball grooves. Remove the cage and inner race
assembly by pulling upward away from the housing
(Fig. 7).
(12) Turn inner cross (driver) 90° to cage and align
one of the race spherical lands with cage window. Raise
land into cage window and remove inner race by
swinging out (Fig. 8).
INSPECT
Check grease for contamination and all parts for
defects as follows:
(1) Wash all parts in suitable solvent and dry, pref-
erably with compressed air.
(2) Inspect housing ball races for excessive wear and
scouring.
(3) Check splined shaft and nut threads for damage.
(4) Inspect all 6 balls for pitting, cracks, scouring
and wear. Dulling of surface is normal.
(5) Inspect cage for excessive wear on inside and
outside spherical surfaces, surface ripples on cage
window, cracks, and chipping.
(6) Inspect inner race (cross) for excessive wear or
scouring of ball races.
Any of the above defects will warrant replacing
the C/V assembly as a unit.
Polished areas in races (cross and housing) and on
cage spheres are normal and do not indicate need for
joint replacement, unless they are suspected of causing
noise and vibration.
Fig. 6 Ball Released
Fig. 7 Removing Cage & Cross Assembly from
Housing
Fig. 8 Removing Cross from Cage
.
FRONT SUSPENSION AND DRIVE SHAFTS
2 - 37
ASSEMBLE
If outer joint was not disassembled nor the
wear sleeve damaged go to step 11.
(1) Position new wear sleeve on joint housing ma-
chined ledge (Fig. 1). Assemble Installer, Special Tool
C-4698 (Tool is provided with handle and dual purpose
drive head for installing wear sleeve onto C/V joint
housing and (head reversed) seal into knuckle). See
KNUCKLE BEARING SEAL.
(2) See (Fig. 1). Assemble tool and install wear
sleeve.
(3) Lightly oil all components before assembling
outer joint.
(4) Align parts according to paint markings.
(5) Insert one of the inner race (cross) lands into cage
window (Fig. 2) and feed race into cage. Pivot cross 90°
to complete cage assembly (Fig. 3).
(6) Align opposing cage windows with housing land
and feed cage assembly into housing (Fig. 4). Pivot cage
90° to complete installation.
When properly assembled the large counterbore in
the cross should be facing outward from the joint on
G.K.N. units (Figs. 3 and 6). On the S.S.G. joint the
internal circlip in the cross will be facing outward from
the housing (Fig. 5).
Fig. 1 Tool Set-Up for Wear Sleeve Installation
Fig. 2 Installing Cross into Cage
Fig. 3 Cage & Cross Assembled G.K.N.
Fig. 4 Installing Cage & Cross into Housing
2 - 38
FRONT SUSPENSION AND DRIVE SHAFTS
.
(7) Apply lubricant to ball races from packet pro-
vided in boot kit and distribute equally between all
sides of ball grooves. One packet is sufficient to lubri-
cate the joint.
(8) Insert balls into raceway by tilting cage and
inner race assembly (Fig. 7).
(9) Fasten boot to shaft. See Boots Install.
(10) On G.K.N. units insert the new circlip, provided
with kit in shaft groove. Do not over expand or twist
circlip during assembly (Fig. 8). The S.S.G. unit has a
reusable circlip retainer that is an integral part of
driver assembly.
Fig. 5 Cage & Cross Assembled S.S.G.
Fig. 6 Cage & Cross Installed in Housing G.K.N.
Fig. 7 Inserting Balls into Raceway
Fig. 8 Installing New Circlip
.
FRONT SUSPENSION AND DRIVE SHAFTS
2 - 39
(11) Position outer joint on splined end with hub nut
on stub shaft. Engage splines, and tap sharply with
mallet (Fig. 9).
(12) Check that circlip is properly seated by attempt-
ing to pull joint from the shaft.
(13) Locate large end of boot over joint housing
checking that boot is not twisted.
(14) Fasten boot to housing. See Boots Install.
C/V JOINT BOOTS
HANDLING AND CLEANING
It is vitally important during any service procedures
requiring boot handling. That care be taken not to
puncture or tear the boot by over tightening clamps,
misuse of tool(s) or pinching the boot. Pinching can
occur by rotating the C/V joints (especially the tripod)
beyond normal working angles.
The driveshaft boots are not compatible with oil,
gasoline, or cleaning solvents. Care must be taken that
boots never come in contact with any of these liquids.
The only acceptable cleaning agent for drive-
shaft boots is soap and water. After washing, boot
must be thoroughly rinsed and dried before re-
using.
B00TS INSPECT
Noticeable amounts of grease on areas adjacent to
and on the exterior of the C/V joint boot. Is the first
indication that a boot is punctured, torn or that a
clamp has loosened. When a C/V joint is removed for
service. The boot should be properly cleaned and in-
spected for cracks, tears and scuffed areas on interior
surfaces. If any of these conditions exist, boot replace-
ment is recommended.
BOOTS INSTALL
THE HARD PLASTIC BOOTS REQUIRE APPROXI-
MATELY 100 TIMES THE CLAMPING FORCE OF
THE RUBBER BOOT. THE CLAMPS USED ON THE
RUBBER BOOTS DO NOT HAVE THE TYPE OF
LOAD CAPACITY REQUIRED. TO SEAL THE HARD
PLASTIC BOOTS AND SHOULD NOT BE USED FOR
THIS PURPOSE.
Rubber boots appear only on the inner joints of
certain driveshafts.
Rubber boots must be serviced with the strap and
buckle clamp. Use the Clamp Installer, Special Tool
C-4653. Proceed with the boot installation as follows:
(1) Slide the small end of the boot over the shaft.
Position the boot to the edge of the locating mark or
groove, whichever is appropriate (Fig. 1).
(2) Install the C/V joint. See Inner or Outer C/V
Joint Assemble.
(3) Slide the large diameter of the boot into the
locating groove on the C/V Joint Housing.
(4) Wrap binding strap around boot twice, PLUS 63
mm (2-1/2 inches) (Fig. 2).
Fig. 9 Position Joint onto Shaft Splines
Fig. 1 C/V Joint Boot Positioning G.K.N.
Fig. 2 Measure & Cut Binding Strap
2 - 40
FRONT SUSPENSION AND DRIVE SHAFTS
.
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