SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHRYSLER2005PT CRUISER TOURING, 2D CONVERTIBLE, 2.4 X, STANDARDREPAIR AND DIAGNOSISDRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESDIFFERENTIAL & DRIVELINECV BOOT - OUTERINSTALLATION
2005 Chrysler PT Cruiser Touring, 2D Convertible, 2.4 X, Standard

CV Boot - Outer: Installation

2005 Chrysler PT Cruiser Touring, 2D Convertible, 2.4 X, StandardSECTION Installation
  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. See Fig 1. 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. 
    Fig 1: Sealing Boot Installation on Interconnecting Shaft
    GC0000061Courtesy of DAIMLERCHRYSLER CORP.
    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. See Fig 2.
    Fig 2: Outer C/V Joint Installation on Interconnecting
    GC0000062Courtesy of DAIMLERCHRYSLER CORP.
    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. See Fig 3.
    Fig 3: Outer C/V Joint Correctly Installed on Interconnecting Shaft
    GC0000063Courtesy of DAIMLERCHRYSLER CORP.
    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. See Fig 4. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. See Fig 5.
    Fig 4: Crimping Tool Installed on Sealing Boot Clamp
    GC0000064Courtesy of DAIMLERCHRYSLER CORP.
    1 - SPECIAL TOOL C-4975A
    2 - INTERCONNECTING SHAFT
    3 - CLAMP
    4 - SEALING BOOT
    Fig 5: Sealing Boot Retaining Clamp Installed
    GC0000065Courtesy of DAIMLERCHRYSLER CORP.
    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. See Fig 6. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. See Fig 7.
    Fig 6: Crimping Tool Installed on Sealing Boot Clamp
    GC0000066Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLAMP
    2 - TRIPOD JOINT HOUSING
    3 - SPECIAL TOOL C-4975A
    4 - SEALING BOOT
    Fig 7: Sealing Boot Retaining Clamp Installed
    GC0000067Courtesy of DAIMLERCHRYSLER CORP.
    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) 
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.