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Home >> Chrysler >> 2001 >> Sebring LX, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (Axle Shafts - Coupe) >> Removal, Disassembly, Reassembly & Installation >> Axle Shafts >> Reassembly (Inner & Outer CV Joint)

Reassembly (Inner & Outer CV Joint)

WARNING: This page is about a different variant/trim than selected.
CAUTION: CV boot sealing is vital to retain lubricant and to prevent contaminants from entering CV joint. Allowing assemblies to dangle unsupported or pulling or pushing on axle ends can cut boots and/or damage CV joints. Axle shafts use no retention system to keep tripod joint in tripod housing. During removal and installation procedures, always support both ends of axle shaft to prevent damage or disengaging tripod joint. DO NOT pull on axle shaft when attempting to remove axle shafts from vehicle.
NOTE: Before reassembling axle shaft components, see Fig 1 for lubrication points.
    NOTE: The value of "W" will change approximately 0.03" (0.70 mm) for each turn on the adjusting bolt. The adjusting bolt should not be turned more than once.
  1. Turn the adjusting bolt on the Crimper Tool (MB991561) so that the size of the opening, "W" is at the standard value of 0.12" (2.9 mm). See Fig 2 . Place the small birfield joint boot band against the projection at the edge of the boot.
    2. CAUTION: Secure the axle shaft in an upright position and clamp the part of the birfield joint boot band to be crimped securely in the jaws of the crimping tool. Crimp the birfield joint boot band. See Fig 3 .
  2. Use the crimping tool to crimp the small birfield joint boot band until the crimping tool touches the stopper. See Fig 2 . Check that crimping amount "B" of the birfield boot band is at the standard value between 0.10-0.11" (2.4-2.8 mm). See Fig 4 . If crimping amount is not within specification, replace the birfield joint boot band as necessary. DO NOT re-use the boot band.
    3. CAUTION: The axle shaft joint uses special grease. DO NOT mix old and new grease or different types of grease.
  3. Fill the inside of the birfield joint boot with the specified amount of the repair kit grease. For models equipped with a 2.4L engine, fill the boot with 3.5-4.3 oz. (100-120 g). For models equipped with 3.0L engines, fill the boot with 3.8-4.6 oz. (110-130 g).
  4. Install the large birfield joint boot band so that the clearance "C", between it and the birfield joint housing is at the standard value of 0.004-0.061" (0.10-1.55 mm). To adjust the size of the opening "W" on the crimping tool to the standard value, see step  1 . Standard value should be 0.13" (3.2 mm).
  5. Place the larger birfield boot band against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by "D" in Fig 5 . Use the crimping tool to crimp the large boot band.
  6. Check that the crimping amount "E" of the birfield joint boot band is at the standard value of 0.10-0.11" (2.4-2.8 mm) and that the crimping amount "F" of the birfield joint boot band is at the limited value of 0.40" (9.5 mm). See Fig 6 . If crimping amount is not within specification, replace the birfield joint boot band as necessary. DO NOT re-use the boot band.
    7. CAUTION: There should be no grease adhered to the rubber part of the dynamic damper. The damper band and the small tripod joint boot band are different in shape. Be careful not to use the wrong band by identifying the color of the band. The damper band uses a blue band. The tripod boot band uses a silver band.
  7. Install the dynamic damper in the position shown in Fig 7 . On the left hand side of the axle shaft, the standard value of "A" should be 9.38-9.62" (239-245 mm). On the right hand side of the axle shaft, the standard value of "A" should be 9.88-10.12" (251-257 mm). Secure the damper bands. Wrap plastic tape around the shaft spline and then install the tripod joint boot band (small) and tripod joint boot. Install the birfield joint assembly.
    8. CAUTION: The axle shaft joint uses special grease. DO NOT mix old and new or different types of grease.
  8. Apply the repair kit grease to the spider axles and rollers of the spider assembly. See Fig 1 . Face the chamfered portion of the spider assembly's spline toward the driveshaft, and then install the spider assembly to the axle shaft. See Fig 8 .
  9. When reassembling right-hand axle components on models equipped with 3.0L engines, Use Snap-In Bar (MB990938) and Installation Adapter (MB990930), press the center bearing into the center bearing bracket. Install the center bearing bracket. See Fig 9 and Figure .
    10. CAUTION: DO NOT damage the rubber portion of the dust seal outer surface when packing the specified grease, otherwise grease will leak.
  10. On all models, when installing the inner and outer dust seals, pack the specified grease in the places shown in Fig 10 . Use only Mopar(R) Multi-Mileage Lubricant, Part No. 2525035 or equivalent. Pack the inner dust seal with the amount of 0.5-0.7 oz. (14-20 g). Pack the outer dust seal with the amount of 0.3-0.4 oz. (8-12 g).
  11. When reassembling the right-hand axle dust seals on models equipped with 3.0L engines, use Dust Seal Installer (MB990890) and press the inner dust seal into the center bearing bracket. Use Dust Seal Installer (MB990890) and Installation Adapter (MB990934) to press the outer dust seal into the center bearing bracket. See Fig 10 .
  12. On all models, apply Mopar(R) Multi-Mileage Lubricant Part No. 2525035 or equivalent to the inside of the inner and outer dust seal lip. DO NOT apply the grease to the outside of the lip.
  13. When reassembling the inner shaft on the right-hand axle on models equipped with 3.0L engines, use Inner Shaft Adapter (MB991172) to hold the center bearing inner race. Press in the inner shaft. See Fig 11 . Install seal plate.
  14. On all models, install tripod joint case. See Figure . Apply the specified grease to the inner shaft serration, and then press the inner shaft assembly into the TJ case. Apply Mopar(R) Multi-mileage Lubricant Part No. 2525035 or equivalent. See Fig 12 .
    15. CAUTION: The axle shaft joint uses special grease. DO NOT mix old and new or different types of grease.
    NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot.
  15. Fill the tripod joint case with repair kit grease and insert the axle shaft. Refill the tripod joint case with repair kit grease. See Fig 13 . For models equipped with 2.4L engines, apply 3.1-3.9 oz. (90-110g). For models equipped with 3.0L engines, apply 3.3-4.0 oz. (95-110 g).
  16. To install the small tripod joint boot band and the large tripod joint boot band, position the tripod joint outer race so that the distance between the boot bands is at the standard value of 3.18-3.42" (82-88 mm). See Fig 14 . Remove part of the tripod joint outer race to release the air pressure inside the boot.
Fig 1: Identifying Lubrication Points
G00201035Courtesy of CHRYSLER CORP.
Fig 2: Adjusting Crimping Tool
G00201036Courtesy of CHRYSLER CORP.
Fig 3: Crimping Birfield Joint Boot Band
G00201037Courtesy of CHRYSLER CORP.
Fig 4: Measuring Crimping Value - Small Boot Band
G00201038Courtesy of CHRYSLER CORP.
Fig 5: Measuring Crimping Value - Large Boot Band (1 Of 2)
G00201040Courtesy of CHRYSLER CORP.
Fig 6: Measuring Crimping Value - Large Boot Band (2 Of 2)
G00213263Courtesy of CHRYSLER CORP.
Fig 7: Installing Dynamic Damper
G00213264Courtesy of CHRYSLER CORP.
Fig 8: Installing Spider Bearing Assembly
G00213265Courtesy of CHRYSLER CORP.
Fig 9: Installing Center Bearing
G00213266Courtesy of CHRYSLER CORP.
Fig 10: Installing Inner & Outer Dust Seal
G00213267Courtesy of CHRYSLER CORP.
Fig 11: Installing Inner Shaft
G00213268Courtesy of CHRYSLER CORP.
Fig 12: Installing Tripod Joint Case & Inner Shaft Assembly
G00213269Courtesy of CHRYSLER CORP.
Fig 13: Lubricating Tripod Joint Case
G00213270Courtesy of CHRYSLER CORP.
Fig 14: Installing Tripod Joint Boot Bands
G00213271Courtesy of CHRYSLER CORP.
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