CV Boot - Inner

Replace the inner CV boot on a 1992 Dodge Viper by removing the halfshaft from the vehicle, separating the inner CV joint, installing a new boot and clamps with fresh grease, and reinstalling the assembly.

Warnings

Tools required

Parts

• Inner CV boot kit (includes boot, clamps, grease) × 1 — Use OEM specification
• Axle nut (if damaged or reuse not permitted) × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification or Mopar RTV

Fluids

• 75W-90 GL-5 with limited-slip additive — 3.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen the rear wheel lug nuts while vehicle is on the ground
3. Loosen (but do not remove) the axle nut on the side being serviced while vehicle is on the ground with brakes applied
4. Raise the rear of vehicle and support securely on jack stands under the frame rails or designated lift points
5. Remove the rear wheel on the side being serviced
6. Place drain pan under differential area to catch fluid spillage

Procedure

1. 1

   Remove axle nut and prepare halfshaft removal
   Remove the axle nut that was loosened during preparation. The axle nut is a large hub-center nut; its retention type (castle nut with cotter pin or staked lock nut) should be verified against the 1992 Viper service manual. Remove and discard the cotter pin if equipped. Set the axle nut aside if reusable, otherwise replace with new. Clean the area around the inboard CV joint where it enters the differential to prevent dirt contamination.
2. 2

   Disconnect inboard CV joint from differential
   The inner CV joint attachment to the differential must be confirmed against the 1992 Viper factory service manual (bolted flange vs. splined circlip-retained stub). Verify the configuration before proceeding. If bolted, remove the CV joint bolts connecting the tripod housing to the differential flange. There are typically 3 bolts arranged in a triangular pattern. Support the halfshaft to prevent it from falling. If the connection is splined (pressed into differential), use a pry bar between the CV joint housing and differential case to carefully pry the joint outward until the retaining circlip releases. Be prepared for differential fluid to drain from the opening.
   ⚠Differential fluid will begin draining immediately when the halfshaft is withdrawn. Keep drain pan positioned.
3. 3

   Remove halfshaft assembly from vehicle
   Pull the outer end of the halfshaft away from the hub assembly. If the outer splines are tight in the hub bearing, tap the end of the shaft with a soft-face hammer or use a puller to press it out from behind the hub. Once the outer splines clear the hub, withdraw the entire halfshaft assembly from the vehicle. Place the halfshaft on a clean workbench for boot service.
4. 4

   Remove old inner CV boot clamps and boot
   Locate the inner CV boot (closest to the differential end). There are two clamps securing the boot: one on the small end (shaft side) and one on the large end (joint housing side). Use boot clamp pliers or side cutters to cut and remove both clamps. Slide the old boot away from the CV joint toward the center of the shaft. Do not remove the outer boot unless it also requires service.
5. 5

   Mark and disassemble inner CV joint
   Before disassembly, use a marker or paint pen to mark the orientation of the tripod spider assembly relative to the shaft and the tripod housing relative to the spider. The Viper uses a tripod-style inner joint. Wipe away excess old grease to expose the retaining components. Locate the snap ring or circlip securing the tripod housing to the spider assembly and remove it with snap ring pliers. Slide the tripod housing off the spider. Locate the snap ring retaining the tripod spider to the shaft and remove it with circlip pliers. Slide the tripod spider off the shaft, noting the orientation of the rollers. Remove the old boot completely from the shaft.
6. 6

   Clean components and inspect
   Thoroughly clean the shaft, tripod spider, rollers, and housing with solvent and shop rags. Remove all old grease and debris. Inspect the tripod rollers for wear, pitting, or flat spots. Inspect the housing inner race surfaces for scoring or wear. Inspect the shaft splines for damage. Replace the entire joint assembly if any wear or damage is found. Clean and dry the boot sealing areas on the shaft and housing.
7. 7

   Install new inner CV boot onto shaft
   Slide the new inner CV boot onto the shaft from the inboard end with the small end toward the center of the shaft. Position the small end of the boot in the groove on the shaft where it will be clamped. Do not install the clamp yet. Ensure the boot is not twisted.
8. 8

   Reassemble tripod spider to shaft
   Pack the tripod spider rollers with approximately one-third of the CV grease supplied in the boot kit. Slide the tripod spider onto the shaft with the previously marked orientation (or with the chamfered edge of the spider facing the shaft if no marks were made). Install the retaining snap ring or circlip into the groove on the shaft to secure the spider. Ensure the snap ring is fully seated in its groove.
9. 9

   Install tripod housing and pack with grease
   Pack the interior of the tripod housing with the remaining two-thirds of the CV grease from the kit. Slide the housing over the tripod spider, aligning with the previously marked orientation. Compress the housing onto the spider and install the retaining snap ring or circlip to secure the housing to the spider assembly. Ensure proper engagement.
10. 10

    Position and clamp new CV boot
    Slide the large end of the boot over the tripod housing and seat it into the boot groove on the housing. Ensure the boot is not twisted and is properly seated in both grooves (shaft and housing). Install the small clamp on the shaft end first, positioning it in the boot groove. Tighten the clamp using boot clamp pliers or the appropriate tool until secure. Install the large clamp on the housing end and tighten securely. Ensure both clamps are tight and the boot is sealed properly with no air pockets. Gently squeeze and release the boot to equalize internal pressure.
11. 11

    Reinstall halfshaft assembly to vehicle
    Guide the outer end of the halfshaft into the hub bearing, aligning the splines. Push or tap the shaft into the hub until the splines are fully engaged. Insert the inner CV joint into the differential. If splined, push the joint into the differential stub shaft until the retaining circlip snaps into place (you should feel or hear a click). If bolted, align the tripod housing flange with the differential flange and install the CV joint bolts finger-tight.
12. 12

    Torque CV joint bolts (if bolted connection)
    If the inner CV joint uses a bolted connection to the differential flange, torque the CV joint bolts to specification in a cross-pattern. This ensures even clamping force and proper alignment.
    Torque spec

    CV Joint Bolts61 Nm (45 lb-ft)
13. 13

    Install and torque axle nut
    Install the axle nut onto the outer stub shaft at the hub. Use a new axle nut if the old one was damaged or if manufacturer specifications require replacement. With the vehicle still on jack stands and the brakes applied (or a pry bar preventing hub rotation), torque the axle nut to specification. Install a new cotter pin through the castle nut slots and stub shaft hole if equipped, or stake the lock nut if that design is used.
    Torque spec

    Axle Nut210 Nm (155 lb-ft)
14. 14

    Refill differential with fluid
    Locate the differential fill plug (typically on the side or top of the differential housing). Remove the fill plug. Using a fluid pump or squeeze bottle, refill the differential with the OEM-specified gear oil (verify viscosity, GL rating, and whether a limited-slip additive is required for the 1992 Viper) until fluid begins to drip from the fill hole. The differential is properly filled when the fluid level reaches the bottom of the fill hole. Reinstall the fill plug and torque to specification if provided, or tighten securely.
15. 15

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel, threading the lug nuts by hand. Lower the vehicle until the tire just contacts the ground to prevent rotation. Torque the wheel lug nuts to specification in a star pattern to ensure even clamping force. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Torque specifications must be followed precisely for axle nut and CV joint bolts to ensure safe operation
2. Ensure boot clamps are tight and properly seated to prevent grease loss and contamination
3. Verify differential fluid level is correct before operating vehicle
4. Check for any fluid leaks around the CV boot and differential after initial test drive

Verification

• Start vehicle and verify no unusual noises from the rear differential or CV joint area
• Test drive vehicle in a safe area, making slow turns in both directions to verify smooth CV joint operation without clicking or binding
• After test drive, inspect the new CV boot for any signs of grease leakage or clamp failure
• Check differential fill plug area for leaks
• Verify axle nut is still properly torqued and cotter pin or stake is secure

More procedures for this vehicle