CV Axles - Front Pair

Replacement of both front CV axles on the 1992 Dodge Viper, requiring suspension disassembly, hub separation, and transmission disconnect.

Warnings

Tools required

Parts

• Front CV axle assembly (driver side) × 1 — Use OEM specification
• Front CV axle assembly (passenger side) × 1 — Use OEM specification
• Axle hub nut (32mm) × 2 — Use OEM specification
• Lower ball joint castle nut × 2 — Use OEM specification or reuse if in good condition
• Cotter pins for ball joint × 2 — Standard size for ball joint castle nut

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Loosen (but do not remove) the 32mm front axle hub nuts on both sides while vehicle is on the ground with wheels bearing weight. This nut requires significant torque to break free.
3. Raise front of vehicle and support securely on jack stands placed under the frame rails.
4. Remove both front wheels.
5. Place drain pans under transmission output shafts to catch any fluid leakage during axle removal.

Procedure

1. 1

   Remove axle hub nut
   With the wheel removed and vehicle supported, fully remove the 32mm axle hub nut from the hub spindle. This nut should already be loosened from preparation steps. Remove and discard the nut; new nuts should be installed during reassembly.
2. 2

   Disconnect lower ball joint
   Remove the cotter pin from the lower ball joint castle nut. Remove the castle nut securing the lower control arm ball joint to the steering knuckle. Use a ball joint separator or pickle fork to separate the ball joint taper from the knuckle. Apply penetrating oil if joint is seized. Strike the knuckle boss area with a hammer while applying separator pressure to aid separation.
3. 3

   Separate outer CV joint from hub
   Push the steering knuckle and hub assembly outward away from the vehicle while pulling the outer CV joint stub shaft out of the hub bearing. The splined shaft should slide free once the axle nut is removed and ball joint is disconnected. If stuck, tap the end of the CV shaft with a dead blow hammer or use a puller to press the shaft from the hub bearing. Be careful not to damage the ABS tone ring (if equipped) on the hub.
4. 4

   Support the axle
   Once the outer end is free from the hub, support the axle assembly with wire or a bungee cord to prevent it from hanging and damaging the inner CV boot during inner joint removal.
5. 5

   Remove inner CV joint from transmission
   Position drain pan directly under the inner CV joint at the transmission. Using a pry bar positioned between the inner CV joint housing and the transmission case, carefully pry the inner CV joint straight out from the transmission output shaft. The joint is retained by a circlip inside the transmission and will require firm steady pressure to release. Avoid prying against the CV boot or aluminum transmission case. Once the circlip releases, pull the entire axle assembly out. Allow any transmission fluid to drain into the pan.
6. 6

   Inspect transmission output seal
   With the axle removed, inspect the transmission output shaft seal for damage, leakage, or wear. Clean the sealing surface area. If the seal shows any deterioration, it should be replaced at this time to prevent future leaks. Note the condition for reassembly.
7. 7

   Repeat for opposite side
   Repeat steps 1 through 6 for the opposite side CV axle. Follow the same sequence: remove hub nut, disconnect lower ball joint, separate outer CV from hub, support axle, remove inner CV from transmission, and inspect seal.
8. 8

   Prepare new CV axles
   Unpack new CV axles and verify correct length and configuration match the removed axles. Check that the inner CV joint circlips are properly seated in their grooves on both new axles. Lightly coat the splines of both inner and outer CV joints with clean transmission fluid or multi-purpose grease to aid installation.
9. 9

   Install inner CV joint to transmission
   Align the inner CV joint splines with the transmission output shaft splines. Push the CV joint straight into the transmission with firm pressure until the circlip engages with an audible click or solid stop. Verify engagement by attempting to pull the axle back out—it should not withdraw. The circlip must be fully seated to retain the axle. Repeat for the opposite side.
10. 10

    Install outer CV joint to hub
    Guide the outer CV joint stub shaft through the steering knuckle and into the hub bearing. Ensure splines are aligned and push the shaft fully into the hub until it seats. The shaft should extend through the hub with threads visible for the axle nut.
11. 11

    Reconnect lower ball joint
    Lift the lower control arm and align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and install the new or reused castle nut. Tighten the castle nut to specification. Align the castle nut slots with the ball joint stud hole and install a new cotter pin. Bend the cotter pin ends to secure. Repeat for the opposite side.
12. 12

    Install new axle hub nuts
    Thread new 32mm axle hub nuts onto the CV joint stub shafts by hand as far as possible. Do not torque at this time—final torque must be applied with vehicle weight on wheels.
13. 13

    Reinstall wheels and lower vehicle
    Install both front wheels and thread lug nuts hand-tight. Carefully lower the vehicle from jack stands until the tires contact the ground but jack stands remain supporting some weight. Tighten wheel lug nuts in a star pattern to specification. Fully lower vehicle and remove jack stands.
14. 14

    Torque axle hub nuts
    With the vehicle on the ground and parking brake engaged, torque both 32mm axle hub nuts to final specification. The high torque requirement necessitates vehicle weight on the wheels to prevent hub rotation during tightening. Apply torque in stages to reach final specification.
15. 15

    Check transmission fluid level
    Check the manual transmission fluid level and top off as necessary with Mopar MS-9224 or 75W-90 GL-4 fluid to compensate for any fluid loss during axle removal. The transmission uses approximately 4.20 quarts total capacity.

Reassembly

1. Torque all fasteners to manufacturer specifications when available.
2. Ensure both inner CV joint circlips have fully engaged in the transmission before considering installation complete.
3. The 32mm axle hub nuts must be torqued with vehicle on the ground to achieve proper specification.
4. New axle hub nuts are recommended as they are typically single-use torque-to-yield design.
5. Verify both lower ball joint castle nuts are properly aligned with cotter pins installed and secured.

Verification

• Test drive the vehicle and verify no clicking, popping, or vibration from the CV axles during acceleration, deceleration, and turning.
• Check for any transmission fluid leaks at the inner CV joint seals after test drive.
• Verify steering and suspension operation is normal with no binding or unusual noises.
• Recheck the 32mm axle hub nut torque after 50-100 miles of driving.
• Inspect CV boots for proper seating and no damage from installation.

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