Dodge Durango

 Service Manual

Differential and Driveline » Front axle driveshafts » Disassembly and assembly
Outer c/v joint

If the outer C/V joint is excessively worn, replace the entire C/V joint and boot.

DISASSEMBLY

(1) Remove retaining clamps from the outer C/V joint and discard. Slide the boot off the outer joint and down the shaft.

(2) Remove the lubricant to expose the outer C/V joint components (Fig. 13).

Fig. 13 Outer C/V Joint Components

1 - RZEPPA JOINT HOUSING (OUTER)

2 - CLAMP

3 - BEARING HUB

4 - BEARING CAGE

5 - SHAFT

6 - CLAMP

7 - BOOT

8 - SNAP RING

9 - BALLS (6)

10 - WASHER

11 - HUB NUT

12 - NUT LOCK

13 - SPRING WASHER

14 - COTTER PIN

(3) Clamp the shaft in a vise (with soft jaws). Support the outer C/V joint.

(4) Use snap ring pliers to release the clip from the groove.

(5) Slide the outer C/V joint from the shaft (Fig.

14).

Fig. 14 Outer C/V Joint Removal

1 - SNAP RING

2 - SNAP RING GROOVE

3 - SNAP RING PLIERS

(6) Remove the slinger, if damaged, from the outer C/V joint. Use a brass drift and a hammer. Tap slinger ring off C/V joint and discard.

(7) Remove the old lubricant. Apply installation alignment marks on the bearing hub, bearing cage and housing with dabs of paint (Fig. 15).

Fig. 15 Ball Access

1 - INSTALLATION ALIGNMENT MARKS

2 - BEARING HUB

3 - BEARING CAGE

4 - CV JOINT HOUSING (OUTER)

(8) Clamp the outer C/V joint in a vertical position.

Place the stub shaft in a soft-jawed vise.

(9) Press down on one side of the bearing cage/hub to tilt the cage. This will provide access to a ball at the opposite side of the cage. If the C/V joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift.

(10) Remove the ball from the bearing cage (Fig.

16). If necessary, a small pry bar can be used to pry the ball loose from the cage.

Fig. 16 Ball Removal

1 - CV JOINT HOUSING (OUTER)

2 - BEARING HUB (UP)

3 - BEARING CAGE (UP)

4 - BALL

(11) Repeat the step above until all six balls are removed from the bearing cage.

(12) Tilt the bearing cage and hub to a vertical position. Remove the cage from the housing. Pull cage upward and away from the housing (Fig. 17).

(13) Turn the bearing hub 90 from the bearing cage. Align one pair of the hub lands with the cage windows. Raise and insert one of the lands into the adjacent cage window. Remove the bearing hub by rolling it out of the cage (Fig. 18).

Fig. 17 Bearing Cage & Hub Removal

1 - CV JOINT HOUSING (OUTER)

2 - BALL RACE

3 - BEARING CAGE WINDOW

Fig. 18 Bearing Hub Removal

ASSEMBLY

(1) Lightly apply lubricating oil to all the outer C/V joint components before assembling them.

(2) Align the bearing hub, cage and housing (Fig.

15) according to the alignment reference marks.

(3) Insert one of the bearing hub lands into a bearing cage window (Fig. 18). Roll the hub into the cage (Fig. 19). Rotate the bearing hub 90 to complete the installation (Fig. 20).

Fig. 19 Bearing Hub Installation

1 - BEARING HUB

2 - BEARING CAGE

Fig. 20 Assembled Bearing Cage & Hub

1 - CAGE WINDOWS

2 - CIRCLIP RETAINER

(4) Insert bearing cage/hub into the housing (Fig.

21). Rotate the cage/hub 90 to complete the installation (Fig. 22).

(5) Apply the lubricant included with the replacement boot to the ball raceways. Spread the lubricant equally between all the raceways. One packet of lubricant is sufficient to lubricate the complete C/V joint.

(6) Tilt the bearing hub and cage and install the balls in the raceways (Fig. 23).

Fig. 21 Bearing Cage & Hub Installation

1 - BALL RACE

2 - BEARING CAGE WINDOW

3 - CV JOINT HOUSING (OUTER)

Fig. 22 Bearing Cage & Hub Installed In Housing

1 - CV JOINT HOUSING (OUTER)

2 - BEARING HUB LARGE COUNTERBORE OUTWARD

3 - BOOT RETAINING SHOULDER

4 - BEARING HUB SMALL COUNTERBORE INWARD

5 - SLINGER

(7) Apply a small amount of lubricant to inner diameter of slinger. Place slinger squarely on the outer C/V joint. Use installer tool L-4518-1 from tool set L-4518 and hammer slinger onto joint until it seats (Fig. 24).

CAUTION: Prevent damage to the slinger after installation or a when a replacement outer C/V joint is installed.

Fig. 23 Ball Installation In Raceway

1 - CV JOINT HOUSING (OUTER)

2 - BEARING HUB (UP)

3 - BEARING CAGE (UP)

4 - BALL

Fig. 24 Slinger Installation

1 - HAMMER

2 - OUTER C.V. JOINT

3 - SLINGER

4 - SPECIAL TOOL L-4518-1

(8) Position the small-diameter end of the replacement boot on the interconnecting shaft. Retain the boot with a replacement clamp.

(9) Apply the required amount of lubricant to the outer C/V joint and boot.

(10) Align the shaft splines to the outer C/V joint splines. Push the outer C/V joint until the snap ring seats in the groove (Fig. 25).

Fig. 25 Outer C/V Joint Installation

1 - SNAP RING

2 - SHAFT TAPER

3 - SNAP RING GROOVE

4 - BEARING HUB

(11) Ensure that the snap ring is properly seated in the housing. Pull the outer C/V joint from the interconnecting shaft to test.

(12) Place the large-diameter end of the replacement boot over the edge of the C/V joint housing.

Ensure that the boot is not twisted.

(13) Retain the boot on the housing with a replacement retaining clamps.

Inner c/v joint

Outer c/v joint