CV Boot - Inner

Replacement of the inner CV boot on a 2005 Dodge Viper, requiring halfshaft removal and disassembly to access the inner tripod joint.

Warnings

Tools required

Parts

• Inner CV boot kit with clamps and grease × 1 — Use OEM specification
• Axle nut cotter pin or stake washer (if applicable) × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification

Fluids

• 75W-140 synthetic GL-5 — 3 qt

Preparation

1. Park vehicle on level ground and engage parking brake.
2. Place wheel chocks behind the front wheels.
3. Loosen rear wheel lug nuts 1/2 turn while vehicle is on the ground.
4. Raise rear of vehicle and support securely on jack stands at manufacturer-recommended lift points.
5. Remove rear wheel completely.

Procedure

1. 1

   Remove axle nut
   With the parking brake engaged, use the correct socket and breaker bar to remove the axle/hub nut from the end of the halfshaft per the factory service manual. Verify the exact socket size and torque value for the 2005 Viper before proceeding, as it requires significant force. Remove and discard the cotter pin or stake washer if present. Replace the axle nut with a new one on reassembly per OEM specification.
2. 2

   Drain differential fluid
   Position a drain pan under the rear differential. Verify whether differential fluid drainage is required to remove the halfshaft on this platform; if the inner joint bolts to an external flange, draining may not be necessary. If draining, remove the differential cover bolts and carefully pry the cover away from the housing. Confirm the exact fluid capacity from the factory service manual before refilling. Remove the cover completely and clean the mating surfaces of old gasket material or RTV.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
3. 3

   Disconnect inner CV joint from differential
   Locate the inner CV joint where it connects to the differential side gear. Remove the bolts securing the inner CV joint flange to the differential stub shaft using the correct socket/driver per the factory service manual (verify exact bolt count and drive type). Support the halfshaft to prevent it from dropping. Carefully pull the halfshaft away from the differential and remove it from the vehicle. The outer CV joint will slide out of the hub assembly.
   Torque spec

   CV Bolts61 Nm (45 lb-ft)
4. 4

   Secure halfshaft and inspect
   Place the halfshaft on a clean workbench with the inner CV joint accessible. Inspect the entire halfshaft for damage, cracks, or excessive grease leakage. Check both boots for tears. If the outer boot or joints show damage, consider replacing the entire halfshaft rather than just the inner boot.
5. 5

   Remove inner boot clamps
   Using CV boot clamp pliers or side cutters, remove both clamps from the inner CV boot (one at the tripod housing, one at the shaft). Slide the boot away from the joint toward the center of the shaft. Wipe away excess grease to expose the tripod joint assembly.
6. 6

   Remove tripod joint
   Locate the snap ring or retaining clip that secures the tripod bearing assembly to the halfshaft. Use snap ring pliers to remove the retaining clip. Mark the orientation of the tripod assembly to the shaft for correct reassembly. Using a brass drift and soft-face hammer, carefully tap the tripod assembly off the shaft splines. The tripod may be tight; apply even pressure around the perimeter. Remove the old boot completely from the shaft.
7. 7

   Clean and inspect components
   Thoroughly clean the halfshaft splines, tripod assembly, and inner CV housing with solvent and a wire brush. Inspect the tripod rollers for pitting, scoring, or flat spots. Check the tripod housing races for wear grooves. Inspect the halfshaft splines for damage. Replace components as necessary if wear is evident.
8. 8

   Install new inner boot
   Slide the new inner CV boot onto the halfshaft from the inner end, with the small end toward the center of the shaft. Position the boot so it will seat properly in the grooves on both the shaft and the tripod housing once installed. Do not install clamps yet.
9. 9

   Reinstall tripod joint
   Apply a thin layer of the supplied CV grease to the halfshaft splines. Align the tripod assembly to the shaft using the orientation marks made during disassembly. Slide the tripod onto the splines until it seats fully. Install the new snap ring or retaining clip to secure the tripod to the shaft. Verify the clip is fully seated in its groove.
10. 10

    Pack joint with grease and install boot
    Pack the tripod housing with the supplied CV grease from the boot kit (typically the entire contents of the grease packet). Work grease into the tripod rollers and housing races. Slide the new boot over the tripod assembly and into position. Ensure the boot lips seat fully in the grooves on both the shaft and the tripod housing. Adjust the boot to eliminate any twisting or stretching.
11. 11

    Install boot clamps
    Install the small boot clamp on the shaft end of the boot and tighten securely using CV boot clamp pliers. Ensure the clamp ears are fully crimped or folded. Install the large boot clamp on the housing end and tighten securely. Verify both clamps are tight and the boot is properly seated with no air pockets or twisting.
12. 12

    Reinstall halfshaft
    Clean the splines on the outer CV joint and apply a light coat of grease. Insert the outer CV joint back into the hub assembly. Align the inner CV joint flange with the differential stub shaft. Install the 6 bolts hand-tight, then torque to specification in a crisscross pattern to ensure even seating.
    Torque spec

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

    Reinstall differential cover and refill
    Install a new differential cover gasket or apply a bead of RTV sealant to the cover mating surface. Position the cover onto the differential housing and install the cover bolts. Torque the bolts in a crisscross pattern to specification. If RTV was used, allow proper cure time per manufacturer instructions before filling. Remove the differential fill plug and add the OEM-specified gear oil until it reaches the bottom of the fill hole. Verify the correct viscosity, GL rating, capacity, and whether a limited-slip friction modifier is required from the factory service manual. Reinstall the fill plug.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
14. 14

    Install axle nut and wheel
    Install a new axle nut onto the halfshaft and torque to the OEM specification using a torque wrench (verify the exact torque value from the factory service manual). Install a new cotter pin through the castle nut slots and halfshaft hole, or stake the nut if equipped with a stake washer. Reinstall the wheel and hand-tighten the lug nuts. Lower the vehicle to the ground and torque the lug nuts to specification in a star pattern.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reassembly follows disassembly steps in reverse order with attention to torque specifications.
2. Ensure all boot clamps are securely crimped to prevent grease loss.
3. Verify the differential is filled to the proper level before test driving.

Verification

• Start the vehicle and listen for unusual noises from the rear axle area.
• Test drive the vehicle at low speed, making tight turns in both directions. Listen for clicking or popping noises that would indicate improper CV joint installation.
• After test drive, inspect the inner CV boot for signs of grease leakage or boot damage.
• Recheck differential fluid level after test drive and top off if necessary.
• Inspect the area around the differential cover for fluid leaks after 50-100 miles of driving.

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