CV Boot - Outer

Replace the outer CV boot on a 2009 Aston Martin DB9, including suspension disassembly, halfshaft removal, boot replacement, and reassembly with proper torque specifications.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps and grease × 1 — Use OEM specification or quality aftermarket equivalent
• Axle nut × 1 — Use OEM specification - single use fastener
• Cotter pin or stake nut hardware × 1 — Check axle nut design for this VIN

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock the rear wheels securely
3. Loosen wheel lug nuts while vehicle is on the ground (do not remove)
4. Raise the front of the vehicle and support securely on jack stands at the manufacturer's recommended jacking points
5. Remove the wheel and tire assembly completely
6. Have a container ready for any grease or fluid drainage

Procedure

1. 1

   Remove axle nut
   With the vehicle on the ground and brakes applied (or with an assistant holding the brakes), use a breaker bar and a correctly sized socket (verify axle nut size against DB9 service data) to loosen the REAR axle nut. Once loosened, raise the vehicle, support on jack stands, and remove the wheel. Fully remove and discard the axle nut. If equipped with a cotter pin, remove and discard it first. This is a single-use fastener and must be replaced. Note: With the vehicle on the ground and brakes applied (or with an assistant holding the brakes), use a breaker bar and the correct size socket (verify size against OEM spec) to loosen the REAR axle/halfshaft nut, as this is a rear-wheel-drive vehicle with driven halfshafts at the rear. Note: With the vehicle on the ground and brakes applied (or with an assistant holding the brakes), use a breaker bar and the correct size socket (verify axle nut size against OEM specification for this VIN) to loosen the axle nut. Note: Axle nut socket (verify exact size against Aston Martin DB9 service data) Note: E-Torx socket set (size range to be verified against Aston Martin DB9 fastener specifications)
2. 2

   Disconnect lower control arm ball joint
   Locate the rear lower control arm/wishbone connection at the rear upright (hub carrier). Remove the fasteners securing the ball joint per OEM spec (verify fastener type and count against factory documentation). Use a ball joint separator to release the taper. Support the lower control arm to prevent sudden dropping. Note: Locate the lower suspension link/ball joint connection at the rear upright (hub carrier) per DB9 rear suspension layout. Note: Fastener count and type to be verified against Aston Martin DB9 service data
3. 3

   Separate outer tie rod end
   This step does not apply to the rear halfshaft on a RWD DB9; the rear suspension has no steering tie rod. Disconnect the applicable rear suspension link (e.g., toe/camber link) per DB9 rear suspension service data instead. Remove the cotter pin first if present. Use a ball joint separator or tie rod puller to separate the tie rod from the knuckle. Do not strike the tie rod end threads directly with a hammer. Note: This step does not apply. The 2009 DB9 is rear-wheel drive; the driven halfshafts are serviced at the rear suspension, which has no steering tie rod ends. Disconnect the appropriate rear suspension links (e.g., upper/lower control arm or toe link) per the OEM procedure to release the rear upright.
4. 4

   Support and remove halfshaft from hub
   Support the outer end of the halfshaft. Pull the rear upright outward while pushing the halfshaft through the hub bearing. If the shaft is tight, use a soft-faced mallet to tap the end of the shaft through the hub. Be careful not to damage the ABS sensor or hub bearing. Once clear, support the halfshaft to prevent strain on the inner CV joint.
5. 5

   Remove halfshaft from vehicle
   With the outer end free, carefully work the halfshaft assembly out from under the vehicle. You may need to angle it to clear suspension components. On this rear-transaxle layout, you will typically need to disconnect the inner CV joint from the rear transaxle/differential output flange by removing the inner flange bolts (verify exact bolt count and type against OEM documentation). Support the halfshaft and remove it to a clean work area. Support the halfshaft and remove it to a clean work area. Note: On the DB9 rear halfshaft you may need to disconnect the inner CV joint from the rear differential/transaxle flange by removing the inner joint flange bolts (verify exact bolt count and type against DB9 service data). Note: On the DB9 the inner joint attaches to the rear differential (transaxle) output flange; disconnect it by removing the inner CV flange bolts (verify exact count and type against factory documentation) if clearance for boot work requires it. Note: On some configurations, you may need to disconnect the inner CV joint from the rear transaxle/differential by removing the inner joint flange bolts (verify exact bolt count and type against Aston Martin DB9 service data)
   Torque spec

   CV Bolts65 Nm (48 lb-ft)
6. 6

   Secure halfshaft and mark orientation
   Clamp the halfshaft in a padded vise at the shaft (never clamp the CV joint housing directly). Use a paint marker to mark the relationship between the outer CV joint housing, inner race, and shaft. This ensures correct reassembly orientation and prevents balance issues.
7. 7

   Remove damaged outer boot and clamps
   Cut away the old boot clamps using wire cutters or clamp pliers. Slide the damaged boot toward the center of the shaft to expose the outer CV joint. Wipe away old grease from the joint and inspect the joint for damage, scoring, or excessive wear on the ball races and cage.
8. 8

   Remove outer CV joint from shaft
   Locate the snap ring or circlip that retains the CV joint to the shaft. This is typically inside the joint housing. Using snap ring pliers, remove the retaining ring. Some joints may require spreading the snap ring while tapping the joint off the shaft with a soft mallet. Match your marks on removal to ensure correct orientation is maintained. Clean the shaft splines thoroughly.
9. 9

   Clean and inspect components
   Using solvent and a parts brush, thoroughly clean the CV joint, shaft splines, and surrounding areas. Inspect the CV joint ball bearings, races, and cage for pitting, cracks, or excessive wear. Check the shaft splines for damage. If any wear or damage is present, replace the entire halfshaft assembly rather than just the boot. Dry all components completely.
10. 10

    Install new boot onto shaft
    Slide the new outer CV boot onto the shaft from the outer end, along with the new boot clamps (small clamp first, then large clamp). Position the boot on the shaft in the groove area but do not clamp yet. Ensure the boot is not twisted.
11. 11

    Reinstall CV joint to shaft
    Pack the CV joint with the grease provided in the boot kit (typically half the supplied grease goes into the joint housing, the remainder in the boot). Align the CV joint to the shaft according to your orientation marks. Slide the joint onto the shaft splines, seating it fully. Install the new snap ring or circlip into its groove, ensuring it is fully seated in the shaft groove.
12. 12

    Position and secure boot
    Slide the boot over the CV joint housing and position it in the grooves on both the shaft and the joint housing. Add the remaining grease from the kit into the boot if not already done. Ensure the boot is not twisted and is seated properly in both grooves. Equalize air pressure by carefully lifting the boot edge with a dull tool. Install the small clamp on the shaft end and tighten using the appropriate clamp tool. Install the large clamp on the CV joint housing end and tighten securely. Ensure clamps are fully seated and secure.
13. 13

    Reinstall halfshaft to vehicle
    Carefully guide the halfshaft assembly back into position under the vehicle. If the inner CV joint was disconnected, align it to the differential flange and install the CV bolts finger-tight first, then torque to specification in a star pattern. Guide the outer splined end through the hub bearing, being careful not to damage the ABS sensor or bearing seals.
    Torque spec

    CV Bolts65 Nm (48 lb-ft)
14. 14

    Reconnect suspension components
    Push the steering knuckle inward and reconnect the lower control arm ball joint. Install the pinch bolt and torque the fasteners to specification. Reconnect the applicable rear suspension link(s) to the upright and torque all fasteners to DB9 specification. Replace any single-use fasteners as required. Note: Reconnect the rear suspension links that were disconnected (e.g., control arm/toe link ball joints), install the fasteners, and torque to OEM specification. Replace any single-use fasteners and install new cotter pins where applicable. Note: Rear suspension link/ball joint torque to be verified against Aston Martin DB9 service data
15. 15

    Install new axle nut and wheel
    Install the new axle nut onto the halfshaft threads. Install the wheel and tire assembly and snug the lug nuts in a star pattern. Lower the vehicle until the tire contacts the ground (to prevent hub rotation). Torque the axle nut to the DB9 manufacturer-specified value (verify in Aston Martin service data before applying — do not assume 300 Nm). Install the cotter pin or stake the nut according to the design. Fully lower the vehicle and torque the wheel fasteners to the DB9 manufacturer-specified value (verify in Aston Martin service data) in a star pattern. Note: Fully lower the vehicle and torque the wheel bolts/lug nuts to the OEM-specified value (verify against factory DB9 documentation) in a star pattern. Note: Torque the axle/halfshaft nut to the OEM-specified value (verify against factory DB9 documentation). Install the cotter pin or stake the nut according to the fastener design. Note: Fully lower the vehicle and torque the wheel fasteners to the OEM-specified value for the 2009 DB9 (verify in factory documentation) in a star pattern. Note: Torque the axle nut to the OEM-specified value for the 2009 DB9 (verify in factory service documentation before final torque). Note: Torque wrench (range to suit verified DB9 axle nut spec, typically up to at least 350 Nm)
    Torque spec

    Axle Nut300 Nm (221 lb-ft)

    Wheel Lug Nuts89 Nm (66 lb-ft)

Reassembly

1. Torque all fasteners to specification in the order removed
2. Ensure all boot clamps are properly tightened and seated in their grooves
3. Verify the axle nut is properly secured with cotter pin or staking as applicable
4. Check that all suspension connections are fully seated and torqued

Verification

• Rotate the wheel by hand to ensure smooth rotation with no binding or clicking from the CV joint
• Check for any grease leakage around the new boot clamps
• Test drive the vehicle and listen for clicking or popping noises during turns, which would indicate improper CV joint installation
• Verify steering response is normal and there is no vibration at highway speeds
• After 50-100 miles, re-check the axle nut torque and wheel lug nut torque

More procedures for this vehicle