Dodge Neon / Neon SRT-4. Manual — part 27
SPECIAL TOOLS
HALFSHAFT
CV BOOT - INNER
REMOVAL
To remove sealing boot from halfshaft for replace-
ment, the halfshaft assembly must be removed from
the vehicle. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/HALF SHAFT - REMOVAL)
The inner tripod joints use no internal retention in
the tripod housing to keep the spider assembly in the
housing. Therefore, do not pull on the interconnect-
ing shaft to disengage tripod housing from transmis-
sion stub shaft. Removal in this manner will cause
damage to the inboard joint sealing boots.
(1) Remove the halfshaft requiring boot replace-
ment from the vehicle. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/HALF SHAFT - REMOVAL)
(2) Remove large boot clamp that retains inner tri-
pod joint sealing boot to tripod joint housing (Fig. 28)
and discard. Then remove small clamp that retains
inner tripod joint sealing boot to interconnecting
shaft and discard. Remove the sealing boot from the
tripod housing and slide it down the interconnecting
shaft.
CAUTION: When removing the spider joint from the
tripod joint housing, hold the rollers in place on the
spider trunions to prevent the rollers and needle
bearings from falling away.
(3) Slide the interconnecting shaft and spider
assembly out of the tripod joint housing (Fig. 29).
(4) Remove snap ring that retains spider assembly
to interconnecting shaft (Fig. 30). Remove the spider
assembly from interconnecting shaft. If spider assem-
bly will not come off interconnecting shaft by hand, it
can be removed by tapping spider assembly with a
brass drift (Fig. 31). Do not hit the outer tripod
bearings in an attempt to remove spider assem-
bly from interconnecting shaft.
(5) Slide sealing boot off interconnecting shaft.
(6) 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 halfshaft assembly
Puller 1026
Boot Clamp Installer C-4975A
Fig. 28 Inner Tripod Joint Sealing Boot Clamps
1 - SMALL CLAMP
2 - LARGE CLAMP
3 - INNER TRIPOD JOINT
4 - SEALING BOOT
5 - INTERCONNECTING SHAFT
Fig. 29 Spider Assembly Joint Removal from
Housing
1 - TRIPOD JOINT HOUSING
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
3 - 12
HALF SHAFT
PL/SRT-4
HALF SHAFT (Continued)
will require replacement. Component parts of
these halfshaft assemblies are not serviceable.
INSTALLATION
NOTE: The inner tripod joint sealing boots are
made from two different types of material. High-
temperature applications (close to exhaust system)
use silicone rubber whereas standard temperature
applications use Hytrel plastic. The silicone sealing
boots are soft and pliable. The Hytrel sealing boots
are stiff and rigid. The replacement sealing boot
MUST BE the same type of material as the sealing
boot that was removed.
(1) Slide inner tripod joint seal boot retaining
clamp, onto interconnecting shaft. Then slide the
replacement inner tripod joint sealing boot onto
interconnecting shaft. Inner tripod joint seal boot
MUST be positioned on interconnecting shaft,
so the raised bead on the inside of the seal boot
is in groove on interconnecting shaft (Fig. 32).
(2) Install spider assembly onto interconnecting
shaft with chamfer on spider assembly toward inter-
connecting shaft (Fig. 33). Spider assembly must be
installed on interconnecting shaft far enough to fully
install spider retaining snap ring. If 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. 34). Do not hit the outer
tripod bearings in an attempt to install spider
assembly on interconnecting shaft.
(3) Install the spider assembly to interconnecting
shaft retaining snap ring into groove on end of inter-
connecting shaft (Fig. 35). 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. 36).
(6) Install inner tripod joint seal boot to intercon-
necting shaft clamp evenly on sealing boot.
(7) Clamp sealing boot onto interconnecting shaft
using crimper, Special Tool C-4975-A and the follow-
ing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 37). Tighten nut on crimping
Fig. 30 Spider Assembly Retaining Snap Ring
1 - INTERCONNECTING SHAFT
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP RING
Fig. 31 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. 32 Sealing Boot Installation on Interconnecting
Shaft
1 - SEALING BOOT
2 - RAISED BEAD IN THIS AREA OF SEALING BOOT
3 - GROOVE
4 - INTERCONNECTING SHAFT
PL/SRT-4
HALF SHAFT
3 - 13
CV BOOT - INNER (Continued)
tool C-4975-A until jaws on tool are closed completely
together, face to face (Fig. 38).
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.
(8) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
CAUTION:
The
following
positioning
procedure
determines the correct air pressure inside the inner
tripod joint assembly prior to clamping the sealing
boot to inner tripod joint housing. If this procedure
is not done prior to clamping sealing boot to tripod
joint housing, boot durability can be adversely
affected.
CAUTION: When venting the inner tripod joint
assembly, use care so inner tripod sealing boot
does not get punctured or, in any other way, dam-
aged. If sealing boot is punctured or damaged while
being vented, the sealing boot can not be used.
Fig. 33 Spider Assembly Installation on
Interconnecting Shaft
1 - SPIDER ASSEMBLY
2 - INTERCONNECTING SHAFT
3 - CHAMFER
Fig. 34 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
Fig. 35 Spider Assembly Retaining Snap Ring
Installed
1 - INTERCONNECTING SHAFT
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP RING
Fig. 36 Installing Tripod Housing on Spider
Assembly
1 - TRIPOD JOINT HOUSING
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
3 - 14
HALF SHAFT
PL/SRT-4
CV BOOT - INNER (Continued)
(9) Insert a trim stick between the tripod joint and
the sealing boot to vent inner tripod joint assembly
(Fig. 39). When inserting trim stick between tri-
pod housing and sealing boot, ensure trim stick
is held flat and firmly against the tripod hous-
ing. If this is not done, damage to the sealing
boot can occur. If inner tripod joint has a Hytrel
(hard plastic) sealing boot, be sure trim stick is
inserted between soft rubber insert and tripod hous-
ing, and not the hard plastic sealing boot and soft
rubber insert.
(10) With trim stick inserted between sealing boot
and tripod joint housing, position inner tripod joint
on halfshaft until correct sealing boot edge to edge
length is obtained for type of sealing boot material
being used (Fig. 40) (Fig. 41). Then remove the trim
stick.
(11) Clamp tripod joint sealing boot to tripod joint
using required procedure for type of boot clamp
application. If seal boot uses crimp type boot clamp,
clamp sealing boot onto tripod housing using crimper,
Special Tool C-4975-A. Place crimping tool C-4975-A
over bridge of clamp (Fig. 42). Tighten nut on crimp-
Fig. 37 Crimping Tool Installed on Sealing Boot
Clamp
1 - SPECIAL TOOL C-4975A
2 - INTERCONNECTING SHAFT
3 - CLAMP
4 - SEALING BOOT
Fig. 38 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. 39 Trim Stick Inserted for Venting Tripod Joint
1 - INNER TRIPOD JOINT SEALING BOOT
2 - SEALING BOOT CLAMP
3 - INNER TRIPOD JOINT HOUSING
4 - TRIM STICK
Fig. 40 Sealing Boot End to End Length with Hytrel
Boot
1 - 107 MILLIMETERS
2 - HYTREL SEALING BOOT
3 - SEALING BOOT CLAMP
4 - INNER TRIPOD JOINT
PL/SRT-4
HALF SHAFT
3 - 15
CV BOOT - INNER (Continued)
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