Dodge Caliber. Manual - part 35

joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod
housing, and not the hard plastic sealing boot and soft rubber insert.

12. With trim stick inserted between sealing boot (2)

and tripod joint housing (4), position inner tripod
joint on halfshaft until correct sealing boot edge to
edge length (1) is obtained for type of sealing
boot material being used. Then remove the trim
stick.

13. With trim stick inserted between sealing boot (2)

14. Clamp (1) tripod joint sealing boot (4) to tripod

joint (2) using required procedure for type of boot
clamp application. If seal boot uses crimp type
boot clamp, clamp sealing boot onto tripod hous-
ing using crimper, Crimping Tool C-4975-A (3).
Place Crimping Tool C-4975-A over bridge of
clamp (1).

HALF SHAFT-FRONT

3 - 15

15. Tighten nut on Crimping Tool C-4975-A (3) until

jaws on tool (4) are closed completely together
(4), face–to–face.

16. If seal boot (3) uses low profile latching type boot

clamp, clamp sealing boot onto tripod housing
using Clamping Tool, Snap-On

YA3050 (2) (or an

equivalent). Place prongs of Clamp Locking Tool
in the holes of the clamp (1).

17. Squeeze tool together until top band of clamp is

latched behind the two tabs (2) on lower band of
clamp.

18. Install the halfshaft requiring boot replacement

back on the vehicle. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/HALF SHAFT - INSTALLATION)

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HALF SHAFT-FRONT

CV BOOT-OUTER

REMOVAL

1. Remove halfshaft assembly requiring boot replace-

ment from vehicle. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/HALF SHAFT - REMOVAL)

2. Remove large boot clamp (4) retaining CV joint

sealing boot to CV joint housing (3) and discard.
Remove small clamp (1) that retains outer CV joint
sealing boot to interconnecting shaft (5) and dis-
card. Remove sealing boot (2) from outer CV joint
housing and slide it down interconnecting shaft.

3. Wipe away grease to expose outer CV joint and

interconnecting shaft.

4. Remove outer CV joint from interconnecting shaft

using the following procedure: Support intercon-
necting shaft in a vise equipped with protective
caps on jaws of vise to prevent damage to inter-
connecting shaft. Then, using a soft–faced hammer
(1), sharply hit the end of the CV joint housing to
dislodge housing from internal circlip (3) on inter-
connecting shaft. Then slide outer CV joint off end
of interconnecting shaft, joint may have to be
tapped off shaft using a soft–faced hammer.

5. Remove large circlip (3) from the interconnecting

shaft (2) before attempting to remove outer CV
joint sealing boot.

6. Slide sealing boot off interconnecting shaft.

7. Thoroughly clean and inspect outer CV joint

assembly and interconnecting joint for any signs of
excessive wear. If any parts show signs of
excessive wear, the halfshaft assembly will
require replacement. Component parts of these
halfshaft assemblies are not serviceable.

HALF SHAFT-FRONT

3 - 17

INSTALLATION

1. Slide new sealing boot clamp (2) onto interconnect-

ing shaft (4). Slide the outer CV joint assembly
sealing boot (1) onto the interconnecting shaft (4).
Seal boot MUST be positioned on interconnect-
ing shaft so the raised bead on the inside of
the seal boot is in groove on interconnecting
shaft.

2. Align splines on interconnecting shaft with splines

on cross of outer CV joint assembly and start outer
CV joint onto interconnecting shaft.

3. Install outer CV joint assembly onto interconnecting

shaft by using a soft–faced hammer (1) and tap-
ping end of stub axle (2) (with hub nut (4) installed)
until outer CV joint (3) is fully seated on intercon-
necting shaft.

4. Outer CV joint assembly must be installed on inter-

connecting shaft until cross (2) of outer CV joint
assembly (3) is seated against circlip on intercon-
necting shaft (1).

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HALF SHAFT-FRONT

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