Replace the inner CV boot on a 1966 Chevrolet Corvette 327ci V8, which requires removing the independent rear suspension halfshaft assembly, disassembling the tripod joint, and installing a new boot with fresh grease.

Warnings

Tools required

Parts

• Inner CV boot kit with clamps and grease × 1 — Use OEM specification or aftermarket IRS halfshaft boot kit
• Differential axle flange gasket × 1 — Use OEM specification
• Differential fluid (if replacing) × 1 — 75W-90 GL-5

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and apply parking brake.
2. Place wheel chocks in front of front wheels.
3. Loosen rear wheel lug nuts while vehicle is on the ground.
4. Raise rear of vehicle and support securely on jack stands under the frame rails.
5. Remove rear wheel on the side being serviced.
6. Place drain pan under differential to catch gear oil.

Procedure

1. 1

   Remove halfshaft from differential
   Locate the 4 bolts securing the inner axle flange to the differential side flange. Use a 19mm wrench or socket to remove all 4 bolts. Pull the halfshaft assembly away from the differential housing. Approximately 1-2 quarts of gear oil will drain from the differential opening. Allow to drain completely into the pan.
2. 2

   Remove halfshaft from wheel hub
   At the wheel hub end, remove the spindle support strut rod if it interferes with halfshaft removal. Remove the outer U-joint strap bolts at the hub flange using a 19mm wrench. There are 2 U-joint strap bolts securing the outer U-joint. Carefully pull the halfshaft assembly free from the hub and remove it completely from the vehicle.
3. 3

   Secure halfshaft for disassembly
   Place the halfshaft assembly on a clean workbench or in a padded vise. If using a vise, clamp gently on the shaft tube itself, not on the joint housings. Position the inner (differential) end for easy access.
4. 4

   Remove damaged inner boot and clamps
   Use side cutters or boot clamp pliers to cut and remove both the large and small clamps from the inner CV boot. Slide the damaged boot away from the tripod housing toward the center of the shaft to expose the joint. Wipe away old grease with shop rags to expose the internal components.
5. 5

   Mark tripod orientation
   Before disassembly, use a paint marker or scribe to mark the orientation of the tripod spider relative to the shaft splines. This ensures correct reassembly phasing and prevents vibration. Mark one tripod arm and the corresponding position on the shaft.
6. 6

   Remove tripod housing
   Slide the tripod housing (tulip) off the tripod spider assembly. It should pull straight off once the boot is moved out of the way. Set the housing aside and inspect for wear or damage to the internal bearing tracks.
7. 7

   Remove tripod snap ring
   Locate the internal snap ring securing the tripod spider to the halfshaft. Use internal snap ring pliers to compress and remove the snap ring. Keep the snap ring in a safe place for reuse unless the boot kit includes a new one.
8. 8

   Remove tripod spider assembly
   Slide or tap the tripod spider assembly off the halfshaft splines. If it is tight, use a brass drift and ball peen hammer to gently tap it off while supporting the shaft. Note the orientation marks made earlier. Remove the old boot completely from the shaft.
9. 9

   Clean and inspect components
   Thoroughly clean the halfshaft splines, tripod spider, and tripod housing with solvent and a wire brush. Inspect the tripod roller bearings for pitting, scoring, or roughness. Inspect the housing tracks for wear. Replace the entire halfshaft assembly if excessive wear is present. Dry all components completely.
10. 10

    Install new inner boot
    Slide the new small boot clamp onto the shaft, followed by the small end of the new CV boot. Position the small end of the boot in the groove on the halfshaft. Ensure the boot is not twisted. Install the small clamp in the boot groove but do not tighten yet.
11. 11

    Reinstall tripod spider
    Align the tripod spider with the orientation marks made during disassembly. Slide the tripod onto the halfshaft splines, ensuring correct phasing. Tap gently with a rubber mallet if needed. The spider should seat fully against the shaft shoulder.
12. 12

    Install tripod snap ring
    Install the snap ring into the groove on the halfshaft to secure the tripod spider. Use snap ring pliers to fully seat the snap ring. Verify the snap ring is completely seated in its groove by attempting to slide the tripod assembly; it should not move axially.
13. 13

    Pack tripod housing with grease
    Place approximately half of the grease packet supplied in the boot kit into the tripod housing. Distribute it evenly among the three bearing tracks. The kit typically includes 3-4 ounces of high-temperature CV grease.
14. 14

    Pack tripod spider and install housing
    Apply the remaining grease from the kit onto the tripod spider roller bearings and between the tripod arms. Slide the tripod housing back onto the tripod spider, ensuring the rollers engage the bearing tracks. Push the housing fully onto the tripod until it seats.
15. 15

    Position and secure boot
    Slide the large end of the boot over the tripod housing and seat it in the boot groove on the housing. Ensure the boot is not twisted and lies flat in both grooves. Install the large boot clamp but do not tighten yet. Burp the boot by carefully lifting the small end edge to release trapped air, then press it back down. Tighten the small clamp first using boot clamp pliers or the appropriate tool, then tighten the large clamp. Verify both clamps are secure and the boot has slight slack (not stretched tight).
16. 16

    Clean differential and halfshaft flanges
    Clean the differential axle flange and the halfshaft flange thoroughly with solvent and shop rags. Remove all old gasket material and gear oil residue. Inspect both flange faces for damage or warping.
17. 17

    Install new flange gasket
    Place a new differential axle flange gasket onto the differential flange. Align the bolt holes. Some applications use a paper gasket, others use RTV sealant; follow the gasket kit instructions.
18. 18

    Reinstall halfshaft to differential
    Align the halfshaft inner flange with the differential flange and gasket. Insert the 4 flange bolts and start them by hand. Tighten the bolts in a cross pattern to ensure even seating. Torque to specification if known, or tighten securely to approximately 40-50 ft-lbs in a cross pattern.
19. 19

    Reinstall halfshaft to wheel hub
    Align the outer U-joint with the hub flange. Install the 2 U-joint straps and bolts. Tighten the strap bolts securely in a cross pattern. Reinstall the spindle support strut rod if it was removed.
20. 20

    Refill differential
    Locate the differential fill plug on the rear cover or side of the differential housing. Remove the fill plug. Using a fluid pump or squeeze bottle, add 75W-90 GL-5 gear oil until it begins to drip from the fill hole. The capacity is approximately 2 quarts. Reinstall and tighten the fill plug.
21. 21

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to specification (typically 80-100 ft-lbs for 1966 Corvette) in a star pattern. Fully lower the vehicle and remove jack stands.

Reassembly

1. Ensure all boot clamps are tight and the boot has no twists or tears.
2. Verify differential is filled to proper level and fill plug is tight.
3. Check that all flange bolts are torqued properly and U-joint straps are secure.
4. Wipe down all components and clean up any spilled gear oil.

Verification

• Start the engine and slowly drive the vehicle forward and backward to verify no clicking, popping, or binding from the halfshaft.
• Inspect the new CV boot for leaks, tears, or improper seating after a short test drive.
• Check under the vehicle for any gear oil leaks at the differential flange gasket.
• Verify smooth operation through turns and acceleration with no vibration or noise from the repaired side.

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