drivetrain

CV Boot - Inner

for 1994–2007 Dodge Ram 2500 5.9L I6 Cummins Diesel · 4WD

Difficulty

Moderate

Time

2.9 h

Tools

Steps

✓Fact-checked. Built from OLP's spec database, then independently fact-checked line by line with every correction applied. Master-tech sign-off by Chris Hackleman is queued. Cross-check torque values against the factory manual, and stop if anything looks unsafe. How our data is made.

This procedure replaces the inner CV boot on the front axle of a 4WD Ram 2500 with the 5.9L Cummins diesel engine, requiring removal of the axle shaft from the differential.

Warnings

⚠Differential fluid will drain when axle shaft is removed. Have drain pan ready immediately upon shaft removal.

⚠The axle shaft is heavy and will pull out suddenly when released from the differential. Support the shaft to prevent injury or damage.

ℹ️Work on a level surface to prevent vehicle movement and ensure accurate fluid fill level when reassembling.

⚠Do not reuse old CV boot clamps. Always use new clamps from the boot kit.

Tools required

Floor jack and jack standsEssential

Torque wrench (15-300 Nm)Essential

1/2 inch drive socket setEssential

Large pry bar or drift punchEssential

CV boot clamp pliers or side cuttersEssential

CV boot clamp installation toolEssential

Drain pan (minimum 4 quarts)Essential

Ball joint separator or pickle fork

Wire brush

Axle shaft puller (if shaft is stuck)

Hammer

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Parts

Inner CV boot kit (includes boot, clamps, and grease) × 1 — Dorman 614-001 or equivalent
CV joint grease (if not included in kit) × 1 — Moly-based high-temp grease
Front differential cover gasket or RTV sealant × 1 — Use OEM specification
New cotter pin for axle nut × 1 — Use OEM specification

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Fluids

75W-90 synthetic gear oil — 3.5 qt

Preparation

Park vehicle on level surface and engage parking brake
Chock rear wheels securely
Loosen wheel lug nuts while vehicle is on ground
Raise front of vehicle and support on jack stands at frame rails
Remove front wheel on side being serviced
Place drain pan under differential to catch gear oil spillage

Procedure

1
Remove axle nut
Remove and discard the cotter pin from the axle nut. If equipped with a staked nut, use a chisel to unstake. Use a breaker bar and large socket to remove the axle nut. Have an assistant apply brakes or use a pry bar against the wheel studs to prevent rotation.
2
Disconnect outer tie rod end
Remove the cotter pin and castle nut from the outer tie rod end. Use a ball joint separator or pickle fork to separate the tie rod end from the steering knuckle. Avoid damaging the tie rod boot during separation.
3
Disconnect upper ball joint
Remove the upper ball joint nut from the steering knuckle. Use a ball joint separator to release the upper ball joint from the knuckle. Support the knuckle and brake assembly to prevent strain on the brake hose.
4
Remove CV joint from axle shaft
Locate the CV joint bolts connecting the outer CV joint to the axle shaft at the differential side. Remove the 6 bolts securing the CV joint. Carefully pull the knuckle assembly outward to separate the outer CV joint from the axle shaft, allowing access to work on the inner boot.
Torque spec
CV Joint Bolts61 Nm (45 lb-ft)
5
Extract axle shaft from differential
Position drain pan directly under the axle shaft entry point. Use a slide hammer with axle puller adapter or carefully pry the axle shaft from the differential housing using a large pry bar. The shaft should pull straight out. Expect immediate fluid drainage. Plug the differential opening with a clean rag to minimize fluid loss.
6
Remove old inner CV boot
Cut and remove the old boot clamps using side cutters or clamp pliers. Slide the damaged boot off the axle shaft. Remove all old grease from the inner CV joint and axle shaft using clean rags. Inspect the CV joint for wear, pitting, or damage. If the joint shows wear, replacement of the entire axle shaft may be necessary.
7
Clean and inspect CV joint
Thoroughly clean the inner CV joint housing, tripod, and axle shaft with solvent and allow to dry. Inspect all bearing surfaces for scoring, pitting, or excessive wear. Check that the tripod moves freely on the shaft splines. Wire brush the boot sealing areas on both the shaft and CV housing to ensure proper boot adhesion.
8
Install new inner CV boot
Slide the small boot clamp onto the axle shaft, followed by the new CV boot (small end first). Position the small end of the boot in the groove on the axle shaft. Install and tighten the small clamp using the boot clamp tool, ensuring it is seated properly in the boot groove.
9
Pack CV joint with grease and secure boot
Pack the entire contents of the grease packet (typically 4-6 oz) into the inner CV joint housing, distributing evenly around the tripod and bearing surfaces. Slide the large end of the boot over the CV housing and seat it in the housing groove. Position the boot so it is not twisted or stretched. Install and tighten the large clamp using the boot clamp tool.
10
Reinstall axle shaft into differential
Remove the rag from the differential opening. Clean the axle shaft splines and apply a light coat of gear oil. Align the shaft splines with the differential side gear and push firmly until the C-clip or retaining ring seats with an audible click. Pull outward on the shaft to verify it is fully engaged and locked in place.
11
Reconnect CV joint to axle shaft
Align the outer CV joint with the axle shaft flange. Install all 6 CV joint bolts and tighten them evenly in a star pattern to specification. Ensure the joint is properly seated before final torquing.
Torque spec
CV Joint Bolts61 Nm (45 lb-ft)
12
Reconnect steering and suspension components
Reconnect the upper ball joint to the steering knuckle and install the nut to specification per factory service manual. Reconnect the outer tie rod end to the steering knuckle and torque the castle nut to specification. Install a new cotter pin through the tie rod castle nut.
13
Install axle nut and wheel
Install the axle nut and tighten to specification. Install a new cotter pin through the axle nut and bend the ends to secure. If equipped with a staked nut, stake the nut collar into the axle groove using a punch. Reinstall the wheel and hand-tighten lug nuts.
Torque spec
Axle Nut250 Nm (184 lb-ft)
14
Refill front differential and final torque
Lower vehicle to the ground. Torque wheel lug nuts to specification in a star pattern. Locate the front differential fill plug on the differential housing. Remove the fill plug and add gear oil of the grade specified in the factory service manual (verify 75W-90, 80W-90, or 75W-140 for your axle) until it reaches the bottom of the fill hole. Reinstall and tighten the fill plug.
Torque spec
Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

Ensure all fasteners are torqued to specification before test driving
Verify axle nut cotter pin is properly installed and bent to prevent loosening
Check that CV boot is not twisted and clamps are tight with no gaps
Top off differential fluid after initial test drive if level has dropped

Verification

Test drive vehicle and listen for clicking or popping noises from the CV joint during turns, which would indicate improper installation or joint damage
Inspect the new CV boot for tears, proper seating, and secure clamps after test drive
Check for differential fluid leaks around the axle shaft seal and fill plug
Verify no grease is being expelled from the boot ends indicating overfilling or improper clamp installation
Confirm proper steering operation with no binding or unusual resistance

🔧Stuck on this cv boot - inner? Take it to The Diag Desk.A human with 20+ years in the bay answers about YOUR Dodge within 24 hours — never AI. $25, and you're not charged unless you get an answer.Ask a tech →