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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: Wheel And Tire Removal
GC0019617Courtesy of DAIMLERCHRYSLER CORP.
1 - WHEEL/TIRE ASSY.
2 - LUG NUT (5)
3 - HUB
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.
CAUTION: The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N.m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.
  1. Disconnect battery negative cable.
  2. Place transaxle in gated park.
  3. Raise vehicle on hoist.
  4. Remove wheel and tire (1) assembly. See Fig 1.
    Fig 2: Halfshaft Retaining Hardware
    GC0022711Courtesy of DAIMLERCHRYSLER CORP.
    1 - COTTER PIN
    2 - WASHER
    3 - HUB NUT
    4 - SPRING WASHER
    5 - NUT LOCK
  5. Remove the cotter pin (1), nut lock (5), and spring washer (4), and hub nut (3) from the end of the outer C/V joint stub axle. See Fig 2.
    Fig 3: Steering Knuckle At Lower Control Arm Ball Joint
    GC0019618Courtesy of DAIMLERCHRYSLER CORP.
    1 - NUT
    2 - BOLT
    3 - BALL JOINT
  6. If equipped with ABS, disconnect the front wheel speed sensor and secure harness out of the way.
  7. Remove nut and bolt (1,2) retaining ball joint stud (3) into steering knuckle. See Fig 3.
    Fig 4: Separating Lower Control Arm From Steering Knuckle
    GC0019619Courtesy of DAIMLERCHRYSLER CORP.
    1 - STEERING KNUCKLE
    2 - PRY BAR
    3 - LOWER CONTROL ARM
    4 - BALL JOINT STUD
    NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged.
  8. Separate ball joint stud (4) from steering knuckle by prying down on lower control arm (3). See Fig 4.
    Fig 5: Separating Halfshaft From Hub/Bearing
    GC0019625Courtesy of DAIMLERCHRYSLER CORP.
    1 - PULLER 1026
    2 - HALFSHAFT
    NOTE: Care must be taken not to separate the inner CV joint during this operation. Do not allow halfshaft to hang by inner CV joint, halfshaft must be supported.
  9. Remove halfshaft (2) from steering knuckle by pulling outward on knuckle while pressing in on halfshaft. Support outer end of halfshaft assembly. If difficulty in separating halfshaft from hub is encountered, See Fig 5. DO NOT strike shaft with hammer,  instead use Puller 1026 (1) to separate.
    Fig 6: Applying Grease To Clean Face Of Outer CV Joint
    GC0041028Courtesy of DAIMLERCHRYSLER CORP.
  10. Support outer end of the halfshaft assembly (1). See Fig 6.
    Fig 7: Halfshaft And Intermediate Shaft (2.2L TD Shown - 2.4L Turbo Similar)
    GC0019626Courtesy of DAIMLERCHRYSLER CORP.
    1 - HALFSHAFT (LH)
    2 - TRANSAXLE
    3 - INTERMEDIATE SHAFT
    4 - BOLT (3)
    5 - HALFSHAFT (RH)
    NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. DO NOT PULL ON INTERCONNECTING SHAFT TO REMOVE, AS THE INNER JOINT WILL BECOME SEPARATED.
    NOTE: When left halfshaft is removed from transaxle, some fluid may leak out.
  11. Remove halfshaft(s) (1,5). See Fig 7. Left halfshaft:  While applying outward pressure on joint by hand, dislodge inner tripod joint from differential side gear by striking outward with a punch at extraction groove. When removing tripod joint and halfshaft, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. Right halfshaft:  Slide inner tripod joint off of intermediate shaft. If difficulty is encountered, dislodge joint from intermediate shaft using punch.
    Fig 8: Halfshaft And Intermediate Shaft - 2.4L Turbo Models
    GC0019627Courtesy of DAIMLERCHRYSLER CORP.
    1 - HALFSHAFT (LH)
    2 - TRANSAXLE
    3 - BOLT
    4 - INTERMEDIATE SHAFT
    5 - HALFSHAFT (RH)
    6 - BOLT (2)
    NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. DO NOT PULL ON INTERCONNECTING SHAFT TO REMOVE, AS THE INNER JOINT WILL BECOME SEPARATED.
    NOTE: When left halfshaft is removed from transaxle, some fluid may leak out.
  12. Remove halfshaft(s) (1,5). See Fig 8. Left halfshaft:  While applying outward pressure on joint by hand, dislodge inner tripod joint from differential side gear by striking outward with a punch at extraction groove. When removing tripod joint and halfshaft, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. Right halfshaft:  Slide inner tripod joint off of intermediate shaft. If difficulty is encountered, dislodge joint from intermediate shaft using punch.
  13. If intermediate shaft is to be removed, remove three intermediate shaft bearing-to-bracket bolts. 2.4L turbo models utilize two (2) intermediate shaft bearing-to-bracket bolts. Remove intermediate shaft bearing/shaft assembly from transaxle.
CAUTION: The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N.m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.
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