Driveaxle boot replacement
Note: Complete rebuilt privacies are available on an exchange basis, which eliminates much time and work. Check on the cost and availability of parts before disassembling the vehicle.
1. Remove the derivative (see Driveaxle — removal and installation).
2. Mount the drive axle in a vise with wood lined jaws (to prevent damage to the axles haft). Check the CV joint for excessive play in the radial direction, which indicates worn parts. Check for smooth operation throughout the full range of motion for each CV joint. If a boot is torn, the recommended procedure is to disassemble the joint, clean the components and inspect for damage due to loss of lubrication and possible contamination by foreign matter.
Disassembly
3. Using diagonal cutters, cut the boot clamps (see illustration), remove the clamps and discard them.
11.3 Cut the old boot clamps off and discard them
4. Using a screwdriver, carefully pry up on the edge of the outer boot and push it away from the CV joint. Old and worn boots can be cut off. Pull the inner CV joint boot back from the housing and slide the housing from the tripod (see illustration).
11.4 Remove the boot from the inner CV joint and slide the tripod from the joint housing
5. Mark the tripod and axle shaft to ensure that they are reassembled properly.
6. Remove the tripod joint snap-ring with a pair of snap-ring pliers (see illustration).
11.6 Remove the snap-ring with a pair of snap-ring pliers
7. Use a hammer and a brass punch to drive the tripod joint from the drive axle (see illustration). Note: The tripod joint must be removed from the drive axle to be able to slide the inner and outer drive axle boots over the drive axle. Do not remove the outer CV joint from the drive axle.
11.7 Drive the tripod joint from the drive axle with a brass punch and hammer; be careful not to damage the bearing surfaces or the splines on the shaft
8. If you haven’t already cut them off, remove both boots.
Check
9. Thoroughly clean all components, including the outer CV joint assembly, with solvent until the old CV joint grease is completely removed. Inspect the bearing surfaces of the inner tripods and housings for cracks, pitting, scoring and other signs of wear. It’s not possible to inspect the bearing surfaces of the inner and outer races of the outer CV joint, but you can at least check the surfaces of the ball bearings themselves (see illustration). If they’re in good shape, the races probably are, too; if they’re not, neither are the races. If the inner CV joint is worn, you can buy a new inner CV joint and install it on the old axle shaft; if the outer CV joint is worn, you’ll have to purchase a new outer CV joint and axle shaft (they’re sold pre-assembled). Check the condition of the bearing for the intermediate shaft (see illustration). It should turn freely and smoothly. If it’s difficult to turn, or makes a grinding noise when rotated, take the intermediate shaft to an automotive machine shop and have a new bearing installed on the shaft.
11.9a Clean the outer CV joint thoroughly with solvent and, working the joint through its entire range of motion, inspect the bearing surfaces of the balls; if they’re worn or damaged, so are the bearing races
11.9b Check the condition of the support bearing on the intermediate shaft. Make sure it turns freely, quietly and smoothly; if the bearing is hard to turn, is noisy or feels rough, have it replaced by an automotive machine shop (be sure to have a pair of new dust covers installed too)
Reassembly
10. Wrap the splines on the inner end of the axle shaft with electrical or duct tape to protect the boots from the sharp edges of the splines (see illustration). Slide the clamps and boots onto the axle shaft, outer boot first, then place the tripod on the shaft and install a new snap-ring. Apply grease to the tripod assembly and inside the housing. Insert the tripod into the housing and pack the remainder of the grease around the tripod (see illustrations). If you’re repacking the outer joint, be sure to work the entire tube of CV joint grease (included with the boot kit) into the bearing assembly.
11.10a Wrap the splined area of the axle shaft with tape to prevent damage to the boots when removing or installing them
11.10b Install the tripod with the recessed portion of the splines facing the axle shaft, then install a new snap-ring
11.10c Install the boot and clamps onto the axle shaft, then insert the tripod into the housing, followed by the rest of the grease
11. Slide the boots into place, making sure the ends of both boots seat in their respective grooves in the axle shaft.
12. Position the inner CV joint mid-way through its range of travel (in/out), then equalize the pressure in the boot and tighten the boot clamps (see illustrations). The drive axle is now ready for installation (see Driveaxle — removal and installation).