Tools You'll Need:
* Jack and jack stands (SAFETY FIRST: Secure the vehicle properly on jack stands before working under it.)
* Wheel chocks
* Lug wrench
* Socket set (metric) including a deep well socket for the axle nut
* Hammer
* Ball joint separator (pickle fork or similar)
* Pry bar
* Penetrating oil (like PB Blaster)
* Replacement CV axle
* Torque wrench
* Safety glasses
* Gloves
Procedure:
1. Preparation: Park on a level surface, engage the parking brake, and chock the rear wheels. Locate the front left wheel.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Disconnect the Brake Caliper: Use a suitable socket to remove the caliper mounting bolts. Carefully hang the caliper out of the way using some wire or a bungee cord to avoid putting stress on the brake line. Do not let the brake line hang freely.
4. Disconnect the ABS Sensor (if applicable): If your Voyager has an ABS system, you might need to unplug the ABS sensor wire from the hub assembly.
5. Remove the Cotter Pin and Castle Nut: Locate the large nut securing the CV axle to the wheel hub. Remove the cotter pin and then carefully unscrew the nut using a deep socket.
6. Separate the Axle from the Hub: This is often the trickiest part. You may need to use a ball joint separator (pickle fork) to gently separate the axle from the hub. Apply penetrating oil beforehand to help loosen things up. Use caution to avoid damaging the hub or axle. A slide hammer can also be helpful here.
7. Remove the Axle from the Transmission: With the axle separated from the hub, you need to remove the inner joint from the transmission. This usually involves prying the axle outward from the transmission. Penetrating oil will again be your friend here.
8. Install the New CV Axle: The installation process is essentially the reverse of the removal. Make sure the new CV axle is properly seated in both the transmission and the wheel hub.
9. Reassembly: Carefully reinstall the axle nut, cotter pin, hub, brake caliper, wheel, and lug nuts. Torque all fasteners to the manufacturer's specifications using a torque wrench. This is crucial to avoid damage and ensure safe operation.
10. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
11. Test Drive: Once everything is reassembled, perform a test drive to check for any vibrations or unusual noises.
Important Considerations:
* Drive Axles are Not Interchangeable: Make absolutely sure you purchase the correct CV axle for your 1997 Plymouth Voyager 3.3L. Get the part number from a reputable auto parts store based on your vehicle's VIN.
* Inner CV Joint Boot: Inspect the inner CV joint boot on the new axle. If it's damaged, replace it immediately. A torn boot will allow grease to escape and contaminants to enter, causing premature failure.
* Wheel Bearing: While you're in there, it's a good idea to inspect the wheel bearing for play or noise. Consider replacing it if necessary.
This is a complex repair, and attempting it without experience could lead to injury or further damage to your vehicle. If you are not comfortable performing this repair yourself, it's highly recommended to take your Voyager to a qualified mechanic. They have the tools, experience, and proper resources to do the job safely and correctly.
