Half Shaft - 500 - Except Electric: Installation

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When the half shaft was removed to service the transmission
, thoroughly clean the spline and oil seal sealing surface on tripod joint.
Lightly lubricate oil seal sealing surface on the tripod joint with fresh clean transaxle fluid.
Holding half shaft assembly by the tripod joint and interconnecting shaft, insert tripod spline shaft through the axle seal and into differential side gear. Engage the splines before applying inward force. Push tripod inward until the lock ring is fully seated in the differential side gear. If lock ring is fully seated, the tripod joint will not be removable from transmission by hand.

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When replacing the half shaft with a new Mopar® service part
, Place the new clamp in the recess on the inner tripod joint boot.
Fill the service inner boot with a pre measured tube of Mopar®, Caplix SIC grease, 68194558AA.
Insert the three way bearing into the tulip tripod socket (1).

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As quickly as possible to avoid spilling the lube from the boot, guide the boot (3) around the perimeter of the tulip socket (1) until it seats in the recess on the outside of the tulip socket (1).
Using tool (special tool #C-4975A, Installer, Axle Clamp), crimp the clamp (2) to hold the tripod boot (3) to the tulip socket (1).

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On Abarth models, RH half shaft, install the bolts (1) to hold the intermediate shaft bearing to the support bracket. Refer to TORQUE SPECIFICATIONS .
Clean all debris and moisture at the bearing hub where the outer CV joint will be installed into steering knuckle assembly.
Insert the outer CV joint spline shaft into the bearing hub.

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Insert the top of the knuckle (3) into the bottom of the MacPherson strut (1).
Insert the bolts (4) through the strut (1) and knuckle (3) and install the nuts (2).
Align the washers on the bolts and nuts with the witness marks on the sides of the strut.
Tighten the nuts (2) to hold the strut to the knuckle to 75 N•m (55 ft. lbs.).

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Install the tie rod end (5) ball stud into the knuckle (3) and start the nut (4) onto the ball stud. While holding the ball stud with a suitable wrench, tighten the nut (4) to 40 N•m (30 ft. lbs.).

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Install the wheel speed sensor head (2) into the knuckle. Install the mounting screw (1) and tighten it to 12 N•m (106 in. lbs.).

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Clean all foreign matter from the threads of the half shaft stub shaft.
Install a NEW hub nut on the end of the half shaft stub shaft and using a 12 point thin-walled 36 mm Craftsman® socket (or equivalent), tighten the hub nut to 310 N•m (229 ft. lbs.). It may be necessary to have a helper applies the brakes to keep the hub from rotating.

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NOTE:
The hub nut must be staked so that it looks as shown in the illustration. Both edges must be split and bent into the shape shown (3). The staking must be opposite of the direction to tighten the nut.
Using tool (special tool #10287, Tool, Front Hub Staking), perform staking procedure.

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Install the tire and wheel assembly. Refer to INSTALLATION .
Check for correct fluid level in transaxle assembly. Refer to STANDARD PROCEDURE .
If equipped, install the engine belly pan. Refer to BELLY PAN, INSTALLATION .
Lower the vehicle.