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Except Diesel And Turbo Models

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Steering Knuckle To C/V Joint Sealing Area
GC0022723Courtesy of DAIMLERCHRYSLER CORP.
1 - STEERING KNUCKLE
2 - WHEEL BEARING
3 - FRONT HUB
4 - THIS AREA OF THE STEERING KNUCKLE IS TO BE FREE OF ALL DEBRIS AND MOISTURE BEFORE INSTALLING HALFSHAFT IN STEERING KNUCKLE
CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the CV joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage CV joints. During removal and installation procedures, always support both ends of the halfshaft to prevent damage.
  1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant.
  2. Holding halfshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand.
  3. Carefully align tripod joint with transaxle side gears. Then grasp halfshaft interconnecting shaft and push tripod joint into transaxle side gear until fully seated. 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 (4). See Fig 1.
    Fig 2: Checking Outer C/V Joint Is Free Of Debris And Moisture
    GC0022724Courtesy of DAIMLERCHRYSLER CORP.
    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.
  5. Ensure that front of outer CV joint (2) which fits into steering knuckle, is free of debris and moisture before assembling into steering knuckle. See Fig 2.
    Fig 3: Applying Grease To Clean Face Of Outer CV Joint
    GC0041028Courtesy of DAIMLERCHRYSLER CORP.
  6. Apply a light coating of Mopar® multi-purpose wheel bearing grease around the circumference of the flat surface (1). See Fig 3. Do not apply too much grease, which could spill on to the non mating and adversely affect the function of the halfshaft. 
  7. Wipe the rear of the hub and bearing in the knuckle clean where they contact the C/V joint.
  8. Install halfshaft back into front hub.
    Fig 4: Halfshaft Installation Into Hub And Knuckle
    GC0022722Courtesy of DAIMLERCHRYSLER CORP.
    1 - NUT
    2 - BOLT
    3 - BALL JOINT
  9. Install steering knuckle onto the ball joint stud (3). See Fig 4.
    NOTE: At this point, the outer joint will not seat completely into the front hub. The outer joint will be pulled into hub and seated when the hub nut is installed and torqued.
  10. Install a NEW  steering knuckle to ball joint stud bolt (2) and nut (1). Tighten the nut and bolt to 95 N.m (70 ft. lbs.).
    Fig 5: Halfshaft Retaining Hardware
    GC0022711Courtesy of DAIMLERCHRYSLER CORP.
    1 - COTTER PIN
    2 - WASHER
    3 - HUB NUT
    4 - SPRING WASHER
    5 - NUT LOCK
  11. Clean all foreign matter from threads of halfshaft outer stub axle. Install washer (2) and hub nut (3) onto the threads of the stub axle and tighten nut (3) to 244 N.m (180 ft. lbs.). See Fig 5.
  12. Install spring washer (4), nut lock (5), and cotter pin (1).
    Fig 6: Wheel And Tire Installation
    GC0022720Courtesy of DAIMLERCHRYSLER CORP.
    1 - WHEEL/TIRE ASSY.
    2 - LUG NUT (5)
    3 - HUB
  13. Install front wheel and tire assembly (1). See Fig 6. Install front wheel lug nuts (2) and tighten to 128 N.m (95 ft. lbs.).
  14. Check for correct fluid level in transaxle assembly.
  15. Lower vehicle.
  16. Connect battery negative cable.
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