Front Half Shaft: Installation: Installation

Fig 1: Steering Knuckle To C/V 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).
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.
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.

Fig 2: Seal Protector, 9099
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NOTE:
Always use Seal Protector (special tool #9099, Seal Protector, Differential Output) when installing half shaft into the transaxle.
Holding halfshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear 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 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.

Fig 3: Lower Bolt Right Halfshaft
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Two wheel drive vehicles install Intermediate Shaft Bracket-to-block (2) and tighten bolt (3) to 75 N.m (55 ft. lbs.).

Fig 4: Upper Bolts Right Side 2wd
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Two wheel drive vehicles install Intermediate Shaft Bracket- to-block upper mounting bolts (2) and tighten to 75 N.m (55 ft. lbs.).

Fig 5: Outer C/V Joint Inspection
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Ensure that front of outer CV joint (2) which fits into steering knuckle, is free of debris and moisture before assembling into steering knuckle.

Fig 6: Applying Grease To Clean Face Of Outer Cv Joint
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Apply a light coating of MOPAR® multi-purpose wheel bearing grease around the circumference of the flat surface (1). Do not apply too much grease, which could spill onto 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 C/V joint.
Install halfshaft back into front hub.

Fig 7: Halfshaft Installation Into Hub And Knuckle
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Install steering knuckle onto the ball joint stud (3).
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 tighten to specification.
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 8: Halfshaft Retaining Hardware
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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.).
Install spring washer (4), nut lock (5), and cotter pin (1).

Fig 9: Left Halfshaft Nut
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SRT 4 install hub nut and tighten to 244 N.m (180 ft. lbs.).

Fig 10: Wheel And Tire Installation
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Install front wheel and tire assembly (1). 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.