CV Boot - Outer

Replace the outer CV boot on a 1992 Dodge Viper by removing the halfshaft from the differential, separating the outer CV joint, and installing a new boot with fresh grease.

Warnings

Tools required

Parts

• Outer CV boot kit (includes boot, clamps, and grease) × 1 — Use OEM specification
• Differential cover gasket (if reusing cover) × 1 — Use OEM specification
• RTV silicone gasket maker (alternative to gasket) × 1 — Mopar or equivalent
• Shop towels × 1 — Generic

Fluids

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

Preparation

1. Park vehicle on level ground and engage parking brake.
2. With vehicle still on ground and brakes applied, use breaker bar to break loose the rear wheel lug nuts on the side being serviced.
3. Break loose the axle nut (32mm or 36mm socket) on the side being serviced while vehicle is still on ground with brakes applied.
4. Raise rear of vehicle and support securely on jack stands rated for vehicle weight, positioned under the rear suspension mounting points.
5. Remove the wheel completely.
6. Position drain pan under differential to catch fluid.

Procedure

1. 1

   Remove axle nut
   Completely remove the axle nut from the end of the halfshaft. This nut was loosened during preparation. Remove and set aside the nut and any washers. Discard the cotter pin if present, as a new one will be required on reassembly.
2. 2

   Remove halfshaft inner CV joint from differential
   Locate the inner CV joint where the halfshaft connects to the differential flange. Remove the CV joint flange bolts securing the inner CV joint to the differential output flange using a socket and ratchet (verify the exact bolt count against the factory service manual). Note the position of any washers or lock tabs. Once bolts are removed, pull the halfshaft away from the differential. Disconnecting the flange-bolted inner joint does not open the differential housing, so significant fluid loss is not expected; keep a rag handy for residual grease.ned correctly.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
3. 3

   Remove halfshaft from hub
   With the inner end disconnected, pull the halfshaft outward from the rear hub assembly. You may need to tap the end of the shaft with a soft mallet or use a pry bar against the hub to break it free. Once clear, remove the entire halfshaft from the vehicle and place on a clean work surface.
4. 4

   Secure halfshaft and mark orientation
   Place the halfshaft in a vise or secure it on a workbench. Before disassembly, mark the relationship between the outer CV joint housing and the shaft with a paint pen or scribe so it can be reassembled in the same orientation.
5. 5

   Remove old boot clamps
   Using diagonal cutters, cut and remove both clamps from the outer CV boot (one large clamp at the CV joint end, one small clamp at the shaft end). Discard the old clamps.
6. 6

   Slide boot away and expose CV joint
   Slide the old boot down the shaft away from the CV joint to expose the joint and grease. Wipe away excess grease with shop rags to expose the internal components.
7. 7

   Remove snap ring and separate CV joint
   Locate the snap ring inside the outer CV joint housing that retains the joint to the shaft. Using snap ring pliers, remove this snap ring. Once the snap ring is removed, pull or tap the CV joint housing off the shaft. You may need to use a brass drift and mallet to tap the inner race to separate it if it is tight. The outer CV joint housing will come off with the balls and cage intact.
8. 8

   Remove old boot and clean shaft
   Slide the old boot completely off the shaft. Thoroughly clean the shaft splines and the area where the new boot will sit using solvent and a wire brush. Inspect the shaft for any damage, burrs, or wear. Remove all old grease residue.
9. 9

   Inspect CV joint components
   Inspect the CV joint housing, balls, cage, and races for wear, pitting, or damage. If any components show excessive wear, the entire CV joint assembly should be replaced rather than just the boot. Clean all components thoroughly if reusing.
10. 10

    Install new boot onto shaft
    Slide the small clamp onto the shaft first, followed by the new boot (small end first). Position the small end of the boot in the groove on the shaft. Install and crimp the small clamp using the CV boot clamp tool to secure the boot to the shaft. Ensure the clamp is tight and properly seated.
11. 11

    Pack CV joint with grease and install
    Pack the CV joint housing with the grease provided in the boot kit, distributing it evenly around the internal components. Also apply grease to the shaft splines. Align the CV joint with your orientation marks and slide it onto the shaft. Install the snap ring to secure the CV joint to the shaft, ensuring it seats fully in its groove.
12. 12

    Position and secure outer boot
    Slide the large end of the boot over the CV joint housing and seat it in the housing groove. Add additional grease from the kit into the boot if needed to ensure the joint is fully packed. Burp the boot by carefully lifting the edge to release any trapped air, then position the large clamp over the boot. Crimp the large clamp securely using the CV boot clamp tool.
13. 13

    Reinstall halfshaft into hub
    Guide the outer end of the halfshaft back through the rear hub assembly. Push it fully into place. Install the axle nut finger-tight for now to hold the shaft in position.
14. 14

    Reconnect inner CV joint to differential
    Align the inner CV joint with the differential output flange, matching the bolt holes. Install the 4 CV joint bolts with any washers or lock tabs in their original positions. Torque the bolts evenly in a criss-cross pattern to specification.
    Torque spec

    CV Joint Bolts61 Nm (45 lb-ft)
15. 15

    Torque axle nut and install wheel
    Torque the axle nut to the factory-specified value (verify in the service manual). Secure the nut using the factory-specified retention method for this vehicle (cotter pin or staked nut). Reinstall the wheel and hand-tighten the lug nuts.
    Torque spec

    Axle Nut210 Nm (155 lb-ft)
16. 16

    Lower vehicle and final torque
    Lower the vehicle to the ground. With the vehicle weight on the wheels, torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
17. 17

    Refill differential fluid
    If differential service is not required for this outer boot job, skip this step. If fluid was lost, locate the differential fill plug (on the side of the differential housing), remove it, and add 75W-90 GL-5 gear oil with limited-slip additive until fluid begins to drip from the fill hole. Verify the exact differential capacity against the factory service manual before servicing. Reinstall the fill plug.

Reassembly

1. Torque specifications are critical for this job, particularly the axle nut (210 Nm) and CV joint bolts (61 Nm).
2. Ensure the new boot clamps are properly crimped with no gaps or sharp edges that could cut the boot.
3. Use all grease provided in the boot kit to ensure adequate lubrication of the CV joint.
4. Verify the snap ring is fully seated in its groove before declaring the CV joint secured.

Verification

• Start the engine and verify no differential fluid leaks from the inner CV joint connection.
• Test drive the vehicle and listen for any clicking, popping, or grinding noises from the CV joint during turns and acceleration.
• Inspect the new boot after test drive for any signs of grease leakage or clamp failure.
• Verify the axle nut remains tight and properly secured with cotter pin or staking.
• Check differential fluid level after test drive and top off if necessary.

More procedures for this vehicle