Diesel And Turbo Models

Fig 1: Halfshaft and Intermediate Shaft - 2.4L Turbo Models

Courtesy of CHRYSLER LLC

1 - HALFSHAFT (LH)

2 - TRANSAXLE

3 - BOLT

4 - INTERMEDIATE SHAFT

5 - HALFSHAFT (RH)

6 - BOLT (2)

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.

If removed, install intermediate shaft/bearing assembly (4) . See Fig 1. Install and torque bearing-to-bracket bolts to 28 N.m (21 ft. lbs.).

Install halfshaft(s) (1,5). Left halfshaft: Thoroughly clean spline and oil seal sealing surface on left tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. While holding halfshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle as far as possible by hand. 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 the female spline by attempting to remove tripod joint from intermediate shaft by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand. Right halfshaft: Thoroughly clean right halfshaft tripod joint spline, as well as intermediate shaft spline. While holding halfshaft assembly by tripod joint and interconnecting shaft, install tripod joint onto intermediate shaft (4) as far as possible by hand.

Fig 2: Steering Knuckle to CV Joint Sealing Area

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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

Clean all debris and moisture out of steering knuckle (4). See Fig 2.

Fig 3: Outer CV Joint Inspection

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1 - OUTER CV JOINT

2 - THIS AREA OF OUTER CV JOINT MUST BE FREE OF ALL DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO STEERING KNUCKLE.

Ensure that front of outer CV joint (1) , which fits into steering knuckle, is free of debris and moisture (2) before assembling into steering knuckle. See Fig 3.

Fig 4: Applying Grease To Face Of Outer CV
Courtesy of CHRYSLER LLC
Apply a light coating of Mopar® multi-purpose wheel bearing grease around the circumference of the flat surface (1) . See Fig 4. Do not apply too much grease, which could spill on to the non mating and adversely affect the function of the halfshaft.
Wipe the rear of the hub and bearing in the knuckle clean where they contact the CV joint.
Install halfshaft back into front hub.

Fig 5: Halfshaft Installation Into Hub And Knuckle
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1 - NUT

2 - BOLT

3 - BALL JOINT
Install steering knuckle onto the ball joint stud (3). See Fig 5.
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.

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 6: Halfshaft Retaining Hardware

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1 - COTTER PIN

2 - WASHER

3 - HUB NUT

4 - SPRING WASHER

5 - NUT LOCK

Clean all foreign matter from threads of halfshaft outer stub axle. Install washer (2) and hub nut onto the threads of the stub axle and tighten nut (3) to 244 N.m (180 ft. lbs.). See Fig 6.

Install spring washer (4), nut lock (5), and cotter pin (1).

Fig 7: Wheel and Tire Installation

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1 - WHEEL/TIRE ASSY.

2 - LUG NUT (5)

3 - HUB

Install front wheel and tire assembly (1). See Fig 7. Install front wheel lug nuts (2) and tighten to 128 N.m (95 ft. lbs.).
Check for correct fluid level in transaxle assembly.
Lower vehicle.
Connect battery negative cable.