Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSPLYMOUTH1994SUNDANCE BASE, 2D HATCHBACK, 2.2 D, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 56 (AXLE SHAFTS - FRONT)OVERHAULINNER CV JOINT ASSEMBLYREASSEMBLY
1994 Plymouth Sundance Base, 2D Hatchback, 2.2 D, Automatic
Inner CV Joint Assembly: Reassembly
1994 Plymouth Sundance Base, 2D Hatchback, 2.2 D, AutomaticSECTION Reassembly
WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 1995 Plymouth Voyager, 1995 Plymouth Grand Voyager, 1995 Dodge Grand Caravan, 1995 Dodge Caravan, and 1995 Chrysler Town & Country. However, it is still accessible from the selected car via links, so may be relevant.
- Install NEW inner CV boot on interconnecting shaft. See CV BOOTS under REMOVAL & INSTALLATION. DO NOT clamp CV boot onto interconnecting shaft at this time.
- To install tripod assembly on interconnecting shaft on single snap ring type tripod, slide tripod onto interconnecting shaft until snap ring groove on end of interconnecting shaft is easily visible. If tripod assembly is difficult to install by hand, use hammer and brass drift to install onto shaft. DO NOT hit tripod bearings to install tripod assembly. Install NEW snap ring making sure it is completely seated in groove around entire circumference of interconnecting shaft.
- Clamp stub shaft end of tripod joint housing into vise equipped with protective caps. To install tripod assembly on interconnecting shaft on double snap ring type tripod, install inner snap ring making sure it is completely seated in groove. Slide tripod onto interconnecting shaft until outer snap ring groove on end of interconnecting shaft is easily visible. If tripod assembly is difficult to install by hand, use hammer and brass drift to install onto shaft. DO NOT hit tripod bearings to install tripod assembly. Install outer snap ring making sure it is completely seated in groove around entire circumference of interconnecting shaft.
- On all inner CV joint assemblies, apply half of grease provided in CV boot service package into tripod joint housing. Place remaining half of grease inside inner CV boot. Install spring cup onto exposed end of spring and position spring in tripod joint housing spring pocket. Place small amount of grease on concave surface of spring cup. Ensure spring remains centered in housing spring pocket when tripod assembly is installed inside housing. See Fig 7 .
- Hold interconnecting shaft at an angle to tripod joint housing while carefully pushing on interconnecting shaft until one tripod bearing is seated in plastic collar of tripod joint housing. See Fig 2 . Change angle of interconnecting shaft and carefully push on interconnecting shaft until all tripod bearings are seated in plastic collar. Position large end of inner CV joint in boot retaining groove on tripod joint housing and clamp in place. See CV BOOTS under REMOVAL & INSTALLATION.
RENDER: 1.0x
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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.