This procedure replaces the outer CV boot on a 1966 Chevrolet Corvette with 327ci V8, though historically this vehicle uses a solid rear axle without CV joints. This procedure assumes a front-wheel-bearing-related modification or non-standard drivetrain configuration.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps × 1 — Use OEM specification
• CV joint grease × 1 — Typically included in boot kit

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack at manufacturer-designated lift points
5. Support vehicle securely on jack stands
6. Remove wheel and tire assembly completely

Procedure

1. 1

   Remove outer tie rod end
   Remove the cotter pin from the outer tie rod end castle nut. Loosen and remove the castle nut. Use a ball joint separator or pickle fork to separate the tie rod end from the steering knuckle. Strike the separator tool with a hammer if necessary to break the taper free.
2. 2

   Support the CV axle assembly
   Position a drain pan or container under the CV axle to catch any grease that may fall during disassembly. Use a pry bar or wooden block to support the axle shaft and prevent it from dropping when loosened.
3. 3

   Remove existing CV boot clamps
   Locate the two clamps securing the outer CV boot (one on the joint end, one on the axle shaft end). Use side cutters to cut through the clamps, or use boot clamp pliers to release them if they are reusable-style clamps. Remove and discard the old clamps.
4. 4

   Slide boot away from CV joint
   Slide the old outer CV boot down the axle shaft away from the CV joint housing to expose the joint completely. Wipe away excess grease with clean rags to inspect the joint and surrounding area.
5. 5

   Inspect and clean CV joint
   Thoroughly inspect the outer CV joint for wear, pitting, or damage on the ball bearings and races. Rotate the joint through its full range of motion and listen for clicking or binding. If damage is present, replace the entire CV axle assembly. If the joint is in good condition, clean all old grease from the joint housing, cage, and balls using clean rags and solvent if necessary.
6. 6

   Remove old boot completely
   Slide the old outer CV boot completely off the axle shaft. Clean the boot seating surfaces on both the CV joint housing and the axle shaft using a wire brush and clean rags. Remove all debris, old grease, and corrosion.
7. 7

   Install new boot onto axle shaft
   Slide the new outer CV boot onto the axle shaft from the inboard end, moving it toward the outer CV joint. Ensure the boot is oriented correctly with the larger diameter opening toward the CV joint housing. Install the small clamp onto the boot but do not tighten yet.
8. 8

   Repack CV joint with grease
   Pack the outer CV joint completely with the CV joint grease provided in the boot kit. Work grease into all ball bearings, races, and the cage. The joint should be fully packed with grease, working it completely through the bearings and cage, with any remaining grease placed inside the boot. Also pack grease into the interior of the new CV boot itself.
9. 9

   Position boot over CV joint
   Carefully slide the new CV boot over the outer CV joint housing, ensuring it seats fully into the grooves on both the axle shaft and the joint housing. Check that the boot is not twisted and is seated evenly all the way around both ends.
10. 10

    Install and secure boot clamps
    Position the small clamp on the axle shaft end of the boot in the designated groove. Using the CV boot clamp tool, crimp or tighten the small clamp securely. Position the large clamp on the CV joint housing end of the boot. Before tightening, equalize air pressure inside the boot by inserting a small flat screwdriver between the boot and housing briefly, then remove. Crimp or tighten the large clamp securely with the clamp tool.
11. 11

    Reconnect outer tie rod end
    Reinstall the outer tie rod end into the steering knuckle taper. Thread the castle nut onto the tie rod stud and tighten to manufacturer specification. Install a new cotter pin through the castle nut and stud, bending the ends to secure.
12. 12

    Reinstall wheel and lower vehicle
    Reinstall the wheel and tire assembly onto the hub. Thread all lug nuts on by hand, then snug them in a star pattern. Lower the vehicle from the jack stands until the tire contacts the ground but does not bear full weight. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands and floor jack.

Reassembly

1. Torque all fasteners to manufacturer specifications where provided
2. Verify all boot clamps are secure and the boot shows no twisting or misalignment
3. Check that no tools or parts have been left in the wheel well or under the vehicle

Verification

• Test drive the vehicle at low speed and turn the steering wheel full lock in both directions, listening for clicking or popping noises from the CV joint
• After test drive, inspect the new outer CV boot for any tears, displacement, or leaking grease
• Verify steering operates smoothly with no binding after tie rod reconnection
• Re-torque wheel lug nuts after 50-100 miles of driving

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