2003 Dodge Pickup R1500 Removal, Disassembly, Reassembly & Installation.pdf

2003 Dodge Pickup R1500 Removal, Disassembly, Reassembly & Installation

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CAUTION: NEVER grasp axle shaft assembly by CV boots, as this may cause boot to pucker or crease and reduce service life of CV boot. Avoid overangulating or stroking CV joints when handling axle shaft assembly. To prevent CV boot deterioration, keep axle shaft assemblies away from battery acid, transmission fluid, brake fluid, differential fluid and gasoline. Removal 1. Have assistant apply brakes, and loosen wheel lug nuts and hub nut. Raise and support vehicle. Remove wheel and tire assembly. Remove hub nut from axle shaft. 2. Remove disc brake caliper mounting pins from caliper adapter, and remove caliper assembly. Support disc brake caliper assembly by using a wire hook and suspending it out of the way.

DO NOT allow caliper to hang by flex hose. Remove caliper adapter mounting bolts, and remove caliper adapter from steering knuckle. Remove brake rotor. 3. Place hydraulic jack under lower suspension arm, and raise jack to unload rebound bumper. Remove lower shock absorber bolt. Remove upper ball joint nut, and separate upper ball joint from steering knuckle with Remover (8677). 4. Support outer end of axle shaft assembly. Insert 2 pry bars between inner CV joint and differential case. Pry against inner CV joint until tripod joint is disengaged from differential axle shaft. Hold inner CV joint and interconnecting shaft of axle shaft. Push steering knuckle outward and push outer CV joint from steering knuckle, without damaging threads on outer CV joint stub axle shaft. Remove front axle shaft from vehicle. Disassembly (Inner CV Joint) 1. Clamp interconnecting shaft of tripod joint housing into vise equipped with protective caps, and support CV joint.

Cut, remove and discard CV boot clamps using a grinder or cut-off wheel without damaging tripod joint housing or interconnecting shaft. Slide CV boot away from tripod joint housing and down interconnecting shaft. 2. Slide tripod joint housing off tripod joint and interconnecting shaft. Remove and discard housing bushing from tripod joint housing. See Fig. 2 . Using snap ring pliers, remove snap ring retaining tripod joint to interconnecting shaft. See Fig. 3 . Remove tripod joint from interconnecting shaft. 3. Slide inner CV boot off interconnecting shaft and discard. Thoroughly clean and inspect tripod joint, tripod joint housing and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, replace tripod CV joint as an assembly. Disassembly (Outer CV Joint) 1. Clamp interconnecting shaft of Rzeppa joint housing into vise equipped with protective caps, and support CV joint. Cut, remove and discard CV boot clamps using a grinder or cut-off wheel without damaging Rzeppa joint housing or interconnecting shaft. Slide CV boot away from Rzeppa joint housing and down interconnecting shaft. 2. Wipe away grease to expose Rzeppa joint snap ring. Using snap ring pliers, spread snap ring and slide Rzeppa joint off interconnecting shaft BEFORE trying to remove outer CV boot. See Fig. 4 . Slide outer CV boot off interconnecting shaft and discard. 3. Clamp stub shaft end of Rzeppa joint housing in soft-jawed vise with Rzeppa joint facing up. Place alignment marks on inner race, cage and Rzeppa joint housing with dabs of paint. See Fig. 5 . Press down on one side of inner race to tilt cage and to gain access to ball on opposite side of cage. See Fig. 6 . If joint is very tight, use brass drift and hammer to tap inner race. DO NOT hit cage. Repeat process until all 6 balls are removed. 4. Turn cage and inner race 90° to position 2 opposing cage windows in area between ball grooves, and pull