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Shaft-Half (Front): Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Left Halfshaft and Intermediate Shaft
GC0014143Courtesy of DAIMLERCHRYSLER CORP.
  1. If previously removed, install intermediate shaft assembly (2). Install four intermediate shaft-to-oil pan bolts and torque to 25 N.m (18 ft. lbs.).
  2. Install left halfshaft assembly (1).
    Fig 2: Axle Seal Installation
    GC0014146Courtesy of DAIMLERCHRYSLER CORP.
  3. Using Tool C-4193-A (1), install new  axle seal.
    Fig 3: Right Halfshaft Removal/Installation
    GC0014144Courtesy of DAIMLERCHRYSLER CORP.
  4. Install right halfshaft assembly (1).
    Fig 4: Locating Halfshaft at Hub/Bearing Assembly
    GC0014038Courtesy of DAIMLERCHRYSLER CORP.
  5. Install halfshaft (1) into hub/bearing assembly (2).
    Fig 5: Locating Axle Shaft Hub Nut
    GC0014039Courtesy of DAIMLERCHRYSLER CORP.
  6. Loosely install halfshaft hub nut (1), and do not tighten at this time.
    Fig 6: View Of Upper Ball Joint, Spindle & Strut Mounting
    GC0014047Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: It is important to tighten nut as described in following step to avoid damaging ball stud joint.
  7. Place upper ball joint stud (1) through hole in top of knuckle and install nut (4). Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 47 N.m + 90° turn (35 ft. lbs. + 90° turn) torque.
    NOTE: Inspect brake shoes (pads) before installation. (Refer to BRAKES/HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES - INSPECTION)
    Fig 7: Locating Clips Retaining Brake Rotor
    GC0014142Courtesy of DAIMLERCHRYSLER CORP.
  8. Clean hub face (1) to remove any dirt or corrosion where rotor mounts.
  9. Install brake rotor (2) over studs on hub and bearing.
    Fig 8: Locating Front Caliper Bolts at Knuckle
    GC0014141Courtesy of DAIMLERCHRYSLER CORP.
  10. Install disc brake caliper and adapter assembly (2) over brake rotor.
  11. Install mounting bolts (1) securing caliper adapter (2) to knuckle (3). Tighten bolts to 169 N.m (125 ft. lbs.) torque.
    Fig 9: Removing/Installing Shock Clevis Pinch Bolt
    GC0014079Courtesy of DAIMLERCHRYSLER CORP.
  12. Pull lower end of shock assembly outward, then slide clevis bracket (3) onto lower end. Slide clevis bracket onto shock assembly until bracket contacts collar on shock housing (2).
  13. Install pinch bolt and nut (1) fastening clevis bracket (3) to bottom of shock assembly (2). Install pinch bolt from rear. Do not tighten at this time. 
    Fig 10: Shock Attachment at Lower Control Arm
    GC0014069Courtesy of DAIMLERCHRYSLER CORP.
    1 - Item_1
    2 - Item _2
  14. Slide clevis bracket (2) over bushing mounted in lower control arm (7).
  15. Install bolt (1) and nut (3) attaching shock clevis bracket (2) to lower control arm (7). Do not tighten at this time. 
    Fig 11: Removing/Installing Shock Clevis Pinch Bolt
    GC0014079Courtesy of DAIMLERCHRYSLER CORP.
  16. Tighten pinch bolt (1) attaching clevis bracket to shock assembly to 61 N.m (45 ft. lbs.) torque.
    Fig 12: Locating Stabilizer Link Attachment at Shock Clevis
    GC0014080Courtesy of DAIMLERCHRYSLER CORP.
  17. Slide stabilizer link ball joint stem into clevis bracket. Install nut (2) fastening link to clevis bracket (3). Tighten nut by holding ball joint stud while turning nut. Tighten nut using crow foot wrench on torque wrench to 146 N.m (108 ft. lbs.) torque.
    Fig 13: Wheel Speed Sensor At Front Knuckle - AWD
    GC0014045Courtesy of DAIMLERCHRYSLER CORP.
  18. Attach wheel speed sensor cable routing clip (3) at knuckle (4).
    Fig 14: Locating Axle Shaft Hub Nut
    GC0014039Courtesy of DAIMLERCHRYSLER CORP.
  19. Install hub nut (1) on end of axle half shaft (2). While a helper applies brakes to keep hub from turning, tighten hub nut to 213 N.m (157 ft. lbs.) torque.
    Fig 15: Tire And Wheel Mounting
    GC0012971Courtesy of DAIMLERCHRYSLER CORP.
  20. Install tire and wheel assembly (1) (Refer to TIRES/WHEELS - INSTALLATION) . Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.) torque.
  21. Lower vehicle.
    Fig 16: Shock Attachment at Lower Control Arm
    GC0014069Courtesy of DAIMLERCHRYSLER CORP.
    1 - Item_1
    2 - Item _2
    NOTE: When tightening lower shock clevis mounting bolt, do not attempt rotating bolt. Bolt shaft is serrated. Turn nut only.
  22. Tighten lower shock clevis bracket bolt nut (3) to 174 N.m (128 ft. lbs.) torque.
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