Dodge Durango (DN). Manual - part 218

(Fig. 7). Verify that the boot and lip are properly
positioned on the intermediate shaft. Position the
clamp locating tabs in the slots and tighten the
clamp.

(4) Compress the clamp bridge with Remover/In-

staller C-4124. Squeeze the tool handles to complete
the tightening of the clamp (Fig. 8). Care must be
exercised when using the tool to avoid cutting
through the clamp bridge or damaging the
boot.

(5) Position the large-diameter end of the boot on

the C/V joint housing.

(6) After the inner joint boot small clamp is

installed, the inboard hub must be set to a service
build length.

(a) Compress the inner hub down the connector

shaft.

(b) Use a small blunt drift between the large

end and the boot seal to relieve the pressure.

flange should be 181.00 mm (7.13 in.). This will
eliminate excess air that can cause a ballooning
affect and possibly cause damage to the boot.
(7) Verify that the boot is not twisted and that it is

correctly positioned on the housing.

(8) Install the large ladder clamp on the boot and

secure as done with the small ladder clamps (Fig. 8).

(9) Slide the outer C/V joint boot small clamp onto

shaft.

(10) Slide outer C/V joint boot onto shaft and into

position on shaft.

(11) Install small clamp to boot as done above.
(12) Install large boot clamp over outer C/V joint.
(13) Install outer C/V joint to shaft.
(14) Install large boot clamp to boot and C/V joint.
(15) Install the C/V driveshaft.

DISASSEMBLY AND ASSEMBLY

INNER C/V JOINT

DISASSEMBLY

(1) Remove the axle driveshaft.
(2) Place the inner C/V joint housing in a vise.
(3) Remove the inner boot retaining clamps. Pull

the inner boot back onto the interconnecting shaft.
Discard the retaining clamps.

(4) Pull the tripod and shaft straight out from the

inner C/V joint housing.

(5) Remove the snap retaining ring from the

groove behind the tripod (Fig. 9). Slide the tripod
toward the center of the shaft. Remove the C-clip on
the outer end of the shaft (Fig. 10).

(6) Remove the tripod from the shaft. Replace the

boot, if necessary.

(7) Remove the lubricant from the interior of the

housing and from the tripod.

(8) Inspect the needle bearing raceways in the

housing and tripod components for excessive wear
and damage. Replace the tripod as a unit only if nec-
essary.

ASSEMBLY

(1) Slide the boot down enough for work access.
(2) Install the snap ring past the ring groove

(toward the center of the shaft). Slide the tripod onto
the end of the interconnecting shaft. Be sure the
chamfered end of the tripod is adjacent to the C-clip
retaining ring groove (Fig. 10).

Fig. 7 Boot Retaining Clamp Locations

1 – POSITION ON FLAT BETWEEN LOCATING SHOULDERS
2 – CLAMPS

Fig. 8 Compressing Clamp Bridge

1 – TOOL C-4124
2 – SLINGER

3 - 22

FRONT AXLE DRIVESHAFTS

REMOVAL AND INSTALLATION (Continued)

(3) Install the C-clip in the groove. Slide the tripod

out against the clip. Install the snap ring in the inner
groove. Be sure the snap ring and C-clip are seated.

(4) Apply the required quantity of lubricant to the

housing and boot. Coat the interior of the joint hous-
ing and the tripod.

(5) Insert and seat the tripod and shaft in the

housing.

(6) Position the large-diameter end of the inner

C/V joint boot over the edge of the housing. Insert
the lip of the boot into the locating groove at the edge
of the housing (Fig. 11).

(7) Insert the small lip into the locating groove in

the interconnecting shaft.

(8) Retain the small–diameter of the boot on the

shaft with a ladder-type clamp in the boot groove.
Verify that the boot and lip are properly positioned
on the intermediate shaft. Position the clamp locat-
ing tabs in the slots and tighten the clamp.

(9) Compress the clamp bridge with Remover/In-

staller C-4124. Squeeze the tool handles to complete
the tightening of the clamp (Fig. 12). Care must be
exercised when using the tool to avoid cutting
through the clamp bridge or damaging the boot.

(10) Position the large-diameter end of the boot on

the C/V joint housing.

Fig. 9 Snap Retaining Ring Removal

1 – SNAP RING
2 – TRIPOD JOINT
3 – SNAP RING PLIERS

Fig. 10 C-Clip Removal/Installation

1 – SNAP RING
2 – CHAMFERED EDGE
3 – C-CLIP GROOVE
4 – C-CLIP
5 – TRIPOD

Fig. 11 Inner C/V Joint Boot

1 – SMALL CLAMP
2 – SEALING BOOT
3 – LARGE CLAMP
4 – INTERCONNECTING SHAFT
5 – INNER TRIPOD JOINT

Fig. 12 Compressing Clamp Bridge

1 – TOOL C-4124
2 – SLINGER

FRONT AXLE DRIVESHAFTS

3 - 23

DISASSEMBLY AND ASSEMBLY (Continued)

(11) After the inner joint boot small clamp is

installed, the inboard hub must be set to a service
build length.

(a) Compress the inner hub down the connector

shaft.

(b) Use a small blunt drift between the large

end and the boot seal to relieve the pressure.

flange should be 181.00 mm (7.13 in.). This will
eliminate excess air that can cause a ballooning
affect and possibly cause damage to the boot.
(12) Verify that the boot is not twisted and that it

is correctly positioned on the housing.

(13) Install the large ladder clamp on the boot and

secure as done with the small ladder clamp (Fig. 12).

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).

(3) Clamp the shaft in a vise (with soft jaws). Sup-

port 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).

(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. 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

Fig. 14 Outer C/V Joint Removal

1 – SNAP RING
2 – SNAP RING GROOVE
3 – SNAP RING PLIERS

Fig. 15 Ball Access

1 – INSTALLATION ALIGNMENT MARKS
2 – BEARING HUB
3 – BEARING CAGE
4 – CV JOINT HOUSING (OUTER)

3 - 24

FRONT AXLE DRIVESHAFTS

DISASSEMBLY AND ASSEMBLY (Continued)

(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.

(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).

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.

Fig. 16 Ball Removal

1 – CV JOINT HOUSING (OUTER)
2 – BEARING HUB (UP)
3 – BEARING CAGE (UP)
4 – BALL

Fig. 17 Bearing Cage & Hub Removal

1 – CV JOINT HOUSING (OUTER)
2 – BALL RACE
3 – BEARING CAGE WINDOW

Fig. 18 Bearing Hub Removal

FRONT AXLE DRIVESHAFTS

3 - 25

DISASSEMBLY AND ASSEMBLY (Continued)

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