1994 Plymouth Voyager Trans Axles

JAMMANCURT

MEMBER
1994 PLYMOUTH VOYAGER
6 CYL
FWD
AUTOMATIC
180,000 MILES

I hve a bad trans axle and cv joint. I am an old retired mechanic with a good tool box. Do you think I can fix this problem? I am on a fixed low income or I would head to the shop of my choice, but I don't have the money. Any advice or short cuts would be appreciated.
thanks

1 Reply

BLUELIGHTNIN6

MECHANIC
16,542 POSTS

I will post replacement procedures and let you decide if you are capable of performing the repairs.

Remove the cotter pin, lockwasher and spring washer from the front axle ends.
Have a helper apply the service brakes and loosen the front axle hub retaining nut.
Raise and support the front of the vehicle on jackstands.
Remove the hub nut, washer and wheel assembly. Drain transaxle fluid.
The speedometer drive pinion must be removed from the transaxle housing before the right side drive axle can be removed. Remove the retaining bolts and lift the pinion with cable connected from the housing.

Remove the clamp bolt that secures the ball joint stud with the steering knuckle.
Separate the ball joint from the knuckle by prying downward against the knuckle connecting point and the control arm. Take care not to damage the rubber boot.
Separate the outer CV-joint (Constant Velocity) splines from the steering knuckle hub by holding the CV housing and pushing the knuckle out and away. If resistance is encountered, use a brass drift and hammer to gently tap the outer hub end of the axle. Do not pry on the outer wear sleeve of the CV-joint.
After the outboard end of the drive axle has been removed from the steering knuckle, support the assembly and pull outward on the inner CV-joint housing to remove the assembly from the transaxle.
WARNING
Do not pull on the shaft or the assembly will disconnect. Pull only on the inner CV-joint housing.
Remove the halfshaft from under the vehicle and service as necessary.
To install:

When installing the halfshaft, hold the inner joint assembly by its housing, align and guide the shaft into the transaxle or intermediate shaft assembly.
Lubricate the outer wear sleeve and seal with multi-purpose grease. Push the steering knuckle outward and install the splined outer shaft into the drive hub.
Install the steering knuckle assembly. Tighten the ball joint clamp bolt to 70 ft. Lbs. (95 Nm). Tighten the hub nut (splined shaft nut) to 180 ft. Lbs. (250 Nm). Refill the transaxle with the proper lubrication fluid.
If after installing the axle assembly, the inboard boot appears collapsed, vent the boot by inserting a thin round rod between the boot and the shaft. Massage the boot until is expands. Install a new clamp to prevent dirt from entering the boot.

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