Dakota 4WD V8-318 5.2L (1991)
badly worn, replace entire joint assembly and boot. If joint is not noisy or excessively worn and grease appears slightly contaminated, proceed to
step 7.
7.
Remove excess grease from joint assembly, then using paint, mark relative positions of inner cross, cage and housing to be used during assembly.
8.
Clamp axle shaft splines in suitable soft jawed vise to position axle shaft vertically. Press down on one side of inner race to tilt cage, then remove
ball from opposite side. Repeat procedure until all balls are removed. If joint is tight, use a hammer and brass drift to tilt race. Do not hit
cage. If balls are tight, they can be pried loose with screwdriver.
9.
Tilt inner race and cage vertically and position two opposite cage windows in area between ball grooves. Pull inner race and cage assembly
upwards to remove from housing.
10.
Rotate inner race 90° to cage, then align one of the race spherical lands with cage window. Raise land into cage, then remove race by swinging
away from cage.
Inspection
1.
Wash all parts in suitable solvent, then dry with compressed air.
2.
Check housing ball races for signs of excessive wear and scouring.
3.
Check splined shaft and nut threads for damage.
4.
Check balls for pitting, cracking, scouring and wear. A slight dulling of ball surface is considered normal.
5.
Check cage for excessive wear on spherical surfaces, surface ripples on cage windows, cracks and chipping.
6.
Check inner race for excessive wear or scouring of ball races.
7.
If any of the above conditions exist, the CV joint assembly should be replaced.
Assembly
1.
Lightly lubricate all components with oil prior to assembly.
2.
Align paint marks, then insert inner race lands into cage window, then feed race into cage. Pivot race 90° to complete installation.
3.
Align opposing cage windows with housing land, then feed cage assembly into housing. Pivot cage 90° to complete installation. Cage is installed
correctly if inner race counterbore is facing outward from joint housing.
4.
Distribute grease included in service package equally between all sides of ball grooves.
5.
Tilt cage and inner race assembly and insert ball, then repeat procedure until all balls are installed.
6.
Fasten boot to axle shaft.
7.
Install new circlip on axle shaft. Do not bend or over extend circlip during installation.
8.
Install joint on axle shaft, engage splines, then tap joint sharply with suitable mallet.
9.
Ensure circlip is engaged by attempting to pull off joint.
10.
Install boot over housing, then install clamp.
11.
If removed, install wear sleeve on housing. Lubricate wear sleeve and seal with MOPAR multipurpose lubricant.
