Replace the inner CV boot on a 2023 Chevrolet Bolt EUV, requiring removal of the axle from the vehicle and disassembly of the inner CV joint.

Warnings

Tools required

Parts

• Inner CV boot kit × 1 — Use OEM specification or quality aftermarket kit with boot, clamps, and grease
• Axle nut × 1 — Replace if staked type or not reusable
• Snap ring (if damaged) × 1 — Included in most CV boot kits

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen but do not remove the front wheel lug nuts on the side being serviced
4. Using a breaker bar and 32mm socket, loosen the axle nut approximately 1/4 turn while vehicle is still on ground (do not remove yet)
5. Raise vehicle with floor jack and support securely on jack stands at manufacturer lift points
6. Remove the wheel completely
7. Position a drain pan under the transaxle area to catch any fluid spillage

Procedure

1. 1

   Remove axle nut
   With the vehicle raised and supported, completely remove the 32mm axle nut that was previously loosened. Remove and discard the nut if it is a staked type. Clean the axle threads with a wire brush.
2. 2

   Separate outer CV joint from hub
   Push the axle shaft inward through the hub bearing to disengage the splines. If needed, use a brass drift and soft mallet to tap the end of the axle shaft. Do not damage the threads. The outer end should push through the hub assembly freely once the nut is removed.
3. 3

   Remove inner CV joint from transaxle
   Using a pry bar positioned between the inner CV joint housing and the transaxle case, carefully pry the inner CV joint out of the transaxle. Apply firm, even pressure until the retaining clip releases and the axle pulls free. Be prepared for some transaxle fluid to drain. Remove the entire axle assembly from the vehicle.
   ⚠Do not pry against the CV boot or damage the transaxle sealing surface. Pry only on the metal CV joint housing.
4. 4

   Secure axle and remove inner boot clamps
   Place the axle assembly on a clean workbench. Using CV boot clamp pliers or side cutters, carefully remove both clamps (large and small) securing the inner CV boot. Do not damage the axle shaft surface. Slide the boot away from the CV joint toward the center of the axle.
5. 5

   Disassemble inner CV joint
   Mark the relationship between the inner CV joint housing and the tripod/spider assembly for reassembly reference. Remove the snap ring that retains the tripod on the axle shaft using snap ring pliers. Slide the CV joint housing off the tripod. Remove the tripod assembly from the axle shaft, noting its orientation. Clean all old grease from all components using solvent and rags.
6. 6

   Remove old boot and inspect components
   Slide the old inner CV boot completely off the axle shaft. Thoroughly inspect the axle shaft for wear, scoring, or damage. Inspect the tripod bearings for smooth rotation, pitting, or wear. Inspect the inner CV joint housing for scoring or damage. Replace any damaged components.
7. 7

   Install new inner boot
   Slide the new inner CV boot onto the axle shaft from the inner end, moving it toward the center of the shaft. Ensure it is positioned in the correct groove area. Install the small boot clamp loosely on the boot but do not tighten yet.
8. 8

   Reassemble CV joint with grease
   Install the tripod assembly onto the axle shaft in the same orientation as removed, aligning with your reference marks. Install the snap ring to secure the tripod. Pack approximately half of the supplied grease from the boot kit into the inner CV joint housing. Install the remaining grease onto the tripod assembly. Slide the CV joint housing over the tripod, aligning the marks made during disassembly.
9. 9

   Secure CV boot
   Slide the inner CV boot over the CV joint housing and position it in the proper groove on both the axle shaft and the CV joint housing. Ensure the boot is not twisted and sits evenly. Secure the small clamp on the axle shaft side using CV boot clamp pliers, crimping it tightly. Secure the large clamp on the CV joint housing side, ensuring the boot is not over-extended or compressed (set axle to normal ride height position). Verify both clamps are tight and secure.
10. 10

    Reinstall axle into transaxle
    Inspect the transaxle seal for damage and replace if necessary. Install a new retaining clip on the inner CV joint stub shaft if equipped. Align the inner CV joint with the transaxle opening and push firmly until the retaining clip snaps into place with an audible click. Pull outward on the axle to confirm it is locked in position.
    ℹ️Ensure the retaining clip is properly seated. The axle should not pull out of the transaxle when tugged.
11. 11

    Install outer CV joint into hub
    Guide the outer CV joint splines into the hub bearing, pushing the axle through until fully seated. Ensure the splines are fully engaged and the axle is not binding.
12. 12

    Install and torque axle nut
    Install a new axle nut onto the axle shaft threads. Using a torque wrench and 32mm socket, torque the axle nut to specification. If the nut is a staked type, stake the nut collar into the axle shaft groove using a punch and hammer. If cotter pin type, install a new cotter pin and bend to secure.
    ⚠Do not reuse staked axle nuts. Always use a new nut if the old one was staked.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Install the wheel onto the hub and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground to prevent rotation. Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Check transaxle fluid level and top off if necessary with ACDelco Dexron VI ATF
2. Test drive the vehicle and listen for any clicking, popping, or vibration from the repaired axle
3. Recheck axle nut torque after 50-100 miles of driving

Verification

• Verify the axle nut is properly torqued and secured with stake or cotter pin
• Confirm no clicking or popping sounds when turning at low speeds
• Check for grease leaks around the inner CV boot after test drive
• Verify no vibration at highway speeds
• Confirm transaxle fluid level is correct and no leaks are present at the axle seal

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