CV Boot - Outer

This procedure covers the replacement of the outer CV boot on a 4WD Dodge Ram 2500 with the 5.9L Cummins diesel engine, requiring removal of the axle shaft from the differential.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps and grease × 1 — Use OEM or equivalent Dana/Spicer kit for Dana 44 or Dana 60 front axle
• Axle hub nut (if not staked type) × 1 — Use OEM specification
• New cotter pin (if equipped) × 1 — Use OEM specification
• Front differential gear oil × 1 — 75W-90 synthetic

Fluids

• 75W-90 synthetic gear oil — 3.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on the ground
3. Raise front of vehicle and support securely on jack stands at frame rails
4. Remove front wheel on the side being serviced
5. Place drain pan under front differential to catch gear oil
6. Allow differential to cool if vehicle was recently driven

Procedure

1. 1

   Remove axle hub nut
   Remove the cotter pin (if equipped) and discard it. Use a breaker bar and appropriate socket to loosen and remove the axle hub nut. This nut is torqued to 184 lb-ft and will require significant force. If the axle spins while loosening, have an assistant apply the brakes or use a pry bar against the wheel studs.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
2. 2

   Remove brake caliper bracket
   Remove the two brake caliper bracket mounting bolts and slide the entire caliper and bracket assembly off the rotor. Support the caliper with wire or a bungee cord from the suspension or frame. Do not let it hang by the brake hose.
3. 3

   Remove hub and rotor assembly
   Remove the rotor by pulling it off the hub studs. The hub bearing assembly may come off with the rotor or stay on the spindle. If the hub stays on the spindle, remove the hub mounting bolts and pull the hub assembly off. This exposes the outer CV joint.
4. 4

   Disconnect outer CV joint from knuckle
   If the CV joint is still attached to the steering knuckle via bolts, remove the CV joint bolts securing the outer joint to the wheel hub. There are typically 6 bolts. Once removed, the outer portion of the axle can be maneuvered away from the knuckle area.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
5. 5

   Separate inner axle shaft from differential
   Locate the inner CV joint bolts connecting the axle shaft to the differential flange. Remove all bolts and carefully pull the inner axle shaft away from the differential. Gear oil will begin draining immediately. Allow fluid to drain into the pan and maneuver the entire axle shaft assembly out from under the vehicle.
   ⚠Gear oil will drain rapidly once the axle is separated. Ensure drain pan is properly positioned.
   Torque spec

   CV Bolts61 Nm (45 lb-ft)
6. 6

   Remove old outer CV boot
   Place the axle shaft on a clean workbench. Use side cutters or a clamp removal tool to cut and remove both clamps securing the outer CV boot. Slide the old boot off the CV joint and shaft. Wipe away old grease from the CV joint, shaft, and surrounding areas using shop rags. Inspect the CV joint for wear, cracks, or damage.
7. 7

   Clean and inspect CV joint
   Thoroughly clean the outer CV joint housing, balls, and cage with solvent or brake cleaner. Inspect all components for pitting, wear, or damage. Rotate the joint through its full range of motion to check for binding or rough spots. If any damage is present, the entire axle shaft should be replaced rather than just the boot.
   ℹ️If the CV joint shows any wear or makes noise during inspection, boot replacement alone will not solve the problem. Replace the entire axle shaft assembly.
8. 8

   Install new outer CV boot
   Slide the new CV boot onto the axle shaft with the small end toward the center of the shaft. Pack the CV joint with the grease supplied in the boot kit, ensuring grease is worked into all ball races and the cage. Also pack grease inside the new boot. Slide the boot over the CV joint and position it in the grooves on both the shaft and the outer joint housing.
   ℹ️Use only the grease provided in the CV boot kit or specified by the manufacturer. Do not substitute with general-purpose grease.
9. 9

   Secure boot clamps
   Install the small clamp on the shaft end first, positioning it in the groove. Use the CV boot clamp tool to crimp the clamp securely. Install the large clamp on the outer joint housing end, ensuring the boot is not twisted or stretched. Crimp the large clamp securely. Verify both clamps are tight and the boot is properly seated in both grooves.
10. 10

    Reinstall axle shaft to differential
    Guide the axle shaft assembly back into position under the vehicle. Align the inner CV joint flange with the differential flange. Install all CV bolts and tighten them to specification using a torque wrench. Ensure the joint is properly seated before final torquing.
    Torque spec

    CV Bolts61 Nm (45 lb-ft)
11. 11

    Reconnect outer CV joint to knuckle
    Position the outer CV joint into the steering knuckle or hub area. If equipped with bolts connecting the outer joint to the hub, install and torque these CV joint bolts to specification. Ensure the joint is fully seated in the hub bore.
    Torque spec

    CV Joint Bolts61 Nm (45 lb-ft)
12. 12

    Reinstall hub, rotor, and caliper
    Install the hub bearing assembly (if removed) and torque mounting bolts. Slide the rotor onto the hub. Position the brake caliper and bracket assembly over the rotor and install the mounting bolts. Torque the caliper bracket bolts to specification.
13. 13

    Install and torque axle hub nut
    Install the new axle hub nut onto the axle shaft. Torque the nut to 184 lb-ft using a torque wrench. If the nut is the castle type, install a new cotter pin through the hole in the axle shaft and bend the ends. If the nut is the staked type, use a punch to stake the nut collar into the axle shaft groove.
    ⚠Always use a new cotter pin or properly stake the axle nut. This is a critical safety component that prevents wheel separation.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
14. 14

    Refill front differential
    Locate the front differential fill plug on the side of the housing. Remove the plug and add 75W-90 synthetic gear oil until it begins to drain from the fill hole. The capacity is approximately 3.5 quarts. Reinstall the fill plug and tighten securely.
15. 15

    Reinstall wheel and lower vehicle
    Install the front wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground. Torque the wheel lug nuts to specification in a star pattern using a torque wrench.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification, particularly the axle nut and CV joint bolts
2. Verify the CV boot is properly seated and both clamps are secure with no gaps
3. Double-check that the differential is filled to the proper level
4. Confirm the brake caliper is properly secured and brake pedal is firm before driving

Verification

• Start the engine and shift the transfer case into 4WD. Drive forward and backward slowly while turning the steering wheel lock-to-lock to verify the CV joint operates smoothly without binding or clicking
• Inspect the new CV boot for any signs of grease leaking from the clamps
• Check the front differential for leaks around the axle shaft seal area
• Test drive the vehicle at low speed in 4WD mode and listen for any abnormal noises from the front axle
• Recheck wheel lug nut torque after 50-100 miles of driving

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