How to Change a CV Half Shaft in a '94 Dodge Intrepid

The 1994 Dodge Intrepid base model came with a 3.3-liter six-cylinder engine and a four-speed automatic transmission. Your vehicle has a front wheel drive configuration, so in order to transfer power from the transmission to the wheels, a special drive shaft with two constant velocity joints is used. This special type of drive shaft allows power to be transferred to the wheels without interruption while the wheels are turn or the suspension is flexed due to bumps or road irregularities. Failure to replace the CV shaft prior to complete failure will result in the vehicle being stranded where it sits.

Instructions

Removal

1

Park the vehicle on a level surface and set the parking brake. Loosen the lug nuts on the wheel to be surface with a lug wrench. Lift the front of the vehicle into the air with a floor jack and place jack stands under the front sub-frame rails. Lower the vehicle until it rests securely on the jack stands.

2

Remove the wheel lug nuts. Remove the wheel and tire from the vehicle and set it aside. Instruct a helper to sit in the vehicle and apply the brakes. Loosen the axle shaft nut with a 34 mm socket and breaker bar. Instruct the helper to exit the vehicle once the axle nut can be removed by hand.

3

Remove the bolts securing the caliper to the steering knuckle with a socket and ratchet. Slide the caliper away from the brake rotor. Hang the caliper from the suspension with mechanics wire, do not allow the caliper to hang from the rubber brake hose. Slide the brake rotor away from the wheel hub and set it aside.

4

Remove the bolt secure the wheel speed sensor harness to the strut assembly with a socket and ratchet. Squeeze the plastic tab and remove the wheel speed sensor harness from the wheel speed sensor. Position the sensor harness aside.

5

Place a pry bar between the inner axle tripod and the transmission case. Pry outward on the axle until the snap ring disengages from the differential side gears, but do not remove the axle shaft from the transmission at this time.

6

Remove the nuts securing the strut to the steering knuckle with a socket and ratchet; use a wrench to hold the bolt steady. Support the steering knuckle by hand and tap the lower strut mounting bolts away from the strut and knuckle. Remove the axle shaft nut and discard it. Rotate the steering knuckle outwards and towards the rear of the vehicle while pulling on the axle shaft to remove the shaft from the wheel hub. Remove the axle shaft from the transmission and remove it from under the vehicle.

Installation

7

Inspect the new axle shaft to ensure a new snap ring is properly installed on the transmission end of the new shaft. Guide the new axle shaft into the transmission and forcefully push the shaft into the transmission until the snap ring properly engages the differential side gears. Pull outward on the inner most axle tripod, the axle will not remove from the transmission by hand when properly installed.

8

Rotate the steering knuckle outward and towards the rear of the car and guide the axle shaft towards the wheel hub. Spline the axle shaft the the wheel hub while pushing the steering knuckle back into position. Align the lower strut mounting flanges with the steering knuckle and push the lower mounting bolts through the strut and knuckle. Install the lower mounting nuts hand tight.

9

Hold the strut mounting bolts steady with a wrench and tighten the mounting nuts to 125 foot-pounds with a torque wrench. Install the new axle nut onto the axle shaft threads hand tight.

10

Slide the brake rotor over the wheel hub. Support the brake caliper by hand and remove the mechanics wire. Slide the brake caliper onto the brake rotor and install the caliper mounting bolts. Tighten the caliper bolts to to 16 foot-pounds with a torque wrench.

11

Instruct a helper to sit in the vehicle and apply the brakes. Tighten the new axle nut to 110 to 130 foot-pounds with a torque wrench. Instruct the helper to exit the vehicle. Install the wheel and tire onto the vehicle and install the lug nuts hand tight.

12

Lift the front of the vehicle off the jack stands and remove the jack stands. Lower the vehicle to the ground. Tighten the lug nuts to 100 foot-pounds in a criss-cross pattern. Drive the vehicle to a local repair shop to have the alignment inspected and adjusted as necessary.