INSTALLATION Chrysler PT Cruiser I

INSTALLATION

Note. The inner tripod joint sealing boots are made from two different types of material. High-temperature applications (close to exhaust system) use silicone rubber whereas standard temperature applications use Hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot that was removed.

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then slide the replacement inner tripod joint sealing boot onto interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. (Scheme 30) 1 - SEALING BOOT 2 - RAISED BEAD IN THIS AREA OF SEALING BOOT 3 - GROOVE 4 - INTERCONNECTING SHAFT
2. Install spider assembly onto interconnecting shaft with chamfer on spider assembly toward interconnecting shaft. (Scheme 31) Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift. (Scheme 32) Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. 1 - SPIDER ASSEMBLY 2 - INTERCONNECTING SHAFT 3 - CHAMFER 1 - DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER ASSEMBLY 2 - SPIDER ASSEMBLY 3 - INTERCONNECTING SHAFT 4 - BRASS DRIFT
3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of interconnecting shaft. (Scheme 33) Be sure the snap ring is fully seated into groove on interconnecting shaft. 1 - INTERCONNECTING SHAFT 2 - SPIDER ASSEMBLY 3 - RETAINING SNAP RING
4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot.
5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft. (Scheme 34) 1 - TRIPOD JOINT HOUSING 2 - SPIDER ASSEMBLY 3 - SEALING BOOT
6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot.
7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. (Scheme 35) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. (Scheme 36) 1 - SPECIAL TOOL C-4975A 2 - INTERCONNECTING SHAFT 3 - CLAMP 4 - SEALING BOOT 1 - CLAMP 2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand.
8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. CAUTION: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing, boot durability can be adversely affected. CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured or, in any other way, damaged. If sealing boot is punctured or damaged while being vented, the sealing boot can not be used.
9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly. (Scheme 37) When inserting trim stick between tripod housing and sealing boot, ensure trim stick is held flat and firmly against the tripod housing. If this is not done, damage to the sealing boot can occur. If inner tripod 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. 1 - INNER TRIPOD JOINT SEALING BOOT 2 - SEALING BOOT CLAMP 3 - INNER TRIPOD JOINT HOUSING 4 - TRIM STICK
10. With trim stick inserted between sealing boot and tripod joint housing, position inner tripod joint on halfshaft until correct sealing boot edge to edge length is obtained for type of sealing boot material being used. (Scheme 38)and (Scheme 39). Then remove the trim stick. 1 - 107 MILLIMETERS 2 - HYTREL SEALING BOOT 3 - SEALING BOOT CLAMP 4 - INNER TRIPOD JOINT 1 - 105 MILLIMETERS 2 - SILICONE SEALING BOOT 3 - CLAMP 4 - INNER TRIPOD JOINT
11. Clamp tripod joint sealing boot to tripod joint using required procedure for type of boot clamp application. If seal boot uses crimp type boot clamp, clamp sealing boot onto tripod housing using crimper, Special Tool C-4975-A. Place crimping tool C-4975-A over bridge of clamp. (Scheme 40) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face-to-face. (Scheme 41) 1 - CLAMP 2 - TRIPOD JOINT HOUSING 3 - SPECIAL TOOL C-4975A 4 - SEALING BOOT 1 - CLAMP 2 - TRIPOD HOUSING 3 - SPECIAL TOOL C-4975A 4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT
12. If seal boot uses low profile latching type boot clamp, clamp sealing boot onto tripod housing using clamp locking tool, Snap-On(R) YA3050 (or an equivalent). Place prongs of clamp locking tool in the holes of the clamp. (Scheme 42) Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp. (Scheme 43) 1 - CLAMP 2 - SPECIAL TOOL YA3050 3 - SEALING BOOT 1 - INNER TRIPOD JOINT HOUSING 2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP 3 - SEALING BOOT
13. Install the halfshaft requiring boot replacement back on the vehicle. «(Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/axle-shafts/#differential-driveline__installation)

Scheme 44

Scheme 45

Scheme 46

1. Remove halfshaft assembly requiring boot replacement from vehicle. «(Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/axle-shafts/#differential-driveline__removal)
2. Remove large boot clamp retaining C/V joint sealing boot to C/V joint housing and discard. Remove small clamp that retains outer C/V joint sealing boot to interconnecting shaft and discard. Remove sealing boot from outer C/V joint housing and slide it down interconnecting shaft. (Scheme 44) 1 - SMALL CLAMP 2 - SEALING BOOT 3 - OUTER C/V JOINT HOUSING 4 - LARGE CLAMP 5 - INTERCONNECTING SHAFT
3. Wipe away grease to expose outer C/V joint and interconnecting shaft.
4. Remove outer C/V joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer, sharply hit the end of the C/V joint housing to dislodge housing from internal circlip on interconnecting shaft. (Scheme 45) Then slide outer C/V joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer. 1 - SOFT HAMMER (TAP INNER RACE ONLY) 2 - WEAR SLEEVE 3 - CIRCLIP (OUTER END OF SHAFT)
5. Remove large circlip from the interconnecting shaft before attempting to remove outer C/V joint sealing boot. (Scheme 46) 1 - SNAP RING PLIERS 2 - INTERCONNECTING SHAFT 3 - CIRCLIP
6. Slide sealing boot off interconnecting shaft.
7. Thoroughly clean and inspect outer C/V 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.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. Slide new sealing boot to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer C/V joint assembly sealing boot onto the interconnecting shaft. (Scheme 47) Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. 1 - SEALING BOOT 2 - RAISED BEAD IN THIS AREA OF SEALING BOOT 3 - GROOVE 4 - INTERCONNECTING SHAFT
2. Align splines on interconnecting shaft with splines on cross of outer C/V joint assembly and start outer C/V joint onto interconnecting shaft.
3. Install outer C/V joint assembly onto interconnecting shaft by using a soft-faced hammer and tapping end of stub axle (with hub nut installed) until outer C/V joint is fully seated on interconnecting shaft. (Scheme 48) 1 - SOFT FACED HAMMER 2 - STUB AXLE 3 - OUTER C/V JOINT 4 - HUB NUT
4. Outer C/V joint assembly must be installed on interconnecting shaft until cross of outer C/V joint assembly is seated against circlip on interconnecting shaft. (Scheme 49) 1 - INTERCONNECTING SHAFT 2 - CROSS 3 - OUTER C/V JOINT ASSEMBLY
5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer C/V joint assembly housing. Put the remaining amount into the sealing boot.
6. Install outer C/V joint sealing boot to interconnecting shaft clamp evenly on sealing boot.
7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. (Scheme 50) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. (Scheme 51) 1 - SPECIAL TOOL C-4975A 2 - INTERCONNECTING SHAFT 3 - CLAMP 4 - SEALING BOOT 1 - CLAMP 2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 3 - INTERCONNECTING SHAFT 4 - SEALING BOOT CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand.
8. Position outer C/V joint sealing boot into its retaining groove on outer C/V joint housing. Install sealing boot to outer C/V joint retaining clamp evenly on sealing boot.
9. Clamp sealing boot onto outer C/V joint housing using Crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. (Scheme 52) Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. (Scheme 53) 1 - CLAMP 2 - TRIPOD JOINT HOUSING 3 - SPECIAL TOOL C-4975A 4 - SEALING BOOT 1 - CLAMP 2 - TRIPOD HOUSING 3 - SPECIAL TOOL C-4975A 4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE 5 - SEALING BOOT
10. Install the halfshaft requiring boot replacement back on the vehicle. «(Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/axle-shafts/#differential-driveline__installation)

See also:
• (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
• (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION)