CV Boot - Outer

Replace the outer CV boot on a 2005 Dodge Viper 8.3L V10, requiring wheel removal, halfshaft separation, and boot replacement with new clamps and grease.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps and grease × 1 — Use OEM specification
• New axle nut × 1 — Use OEM specification
• New cotter pin (if applicable) × 1 — Check axle nut retention method

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock the front wheels to prevent rolling
3. Loosen the rear wheel lug nuts while vehicle is on the ground (do not remove)
4. With the axle nut still supporting the hub, loosen (but do not remove) the axle nut using a breaker bar and appropriate socket while vehicle is on the ground
5. Raise rear of vehicle and support securely on jack stands at the rear jacking points
6. Remove the rear wheel completely

Procedure

1. 1

   Remove axle nut
   Fully remove the previously loosened axle nut from the end of the halfshaft. If equipped with a cotter pin, remove and discard it first. Set the nut aside as it should be replaced with a new one during reassembly.
2. 2

   Disconnect halfshaft from hub
   The Viper halfshaft is bolted at both ends via flanges rather than passing through the hub on splines. Verify the outer end attachment method against the factory service manual before separation, and do not attempt to drive a splined shaft out of the hub.
3. 3

   Support halfshaft and access inner CV joint
   Support the halfshaft with a bungee cord or wire to prevent it from hanging by the inner CV joint. Locate the inboard CV joint connection point at the differential or intermediate shaft. You will need access to separate the shaft, but the outer boot can be replaced with the shaft partially attached.
4. 4

   Remove halfshaft from vehicle
   At the differential end, remove the bolts securing the inner CV joint flange to the differential output flange (verify exact count and bolt type against the factory service manual). Use a pry bar to carefully separate the joint. Separating the bolted CV flange does not open the differential housing, so no differential fluid should escape. Once freed, pull the entire halfshaft assembly out through the hub area and place on a clean workbench.
   Torque spec

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

   Cut and remove old outer CV boot
   Using diagonal cutters or a utility knife, carefully cut both clamps securing the outer CV boot (the boot closest to the wheel end of the shaft). Slide the old boot off the CV joint and down the shaft. Do not cut into the shaft itself.
6. 6

   Clean outer CV joint
   Wipe away all old grease from the outer CV joint, joint housing, and shaft using clean rags. Inspect the joint for any signs of wear, scoring, or damaged balls/races. Use brake cleaner sparingly if needed, but ensure the joint is completely dry before repacking. Rotate the joint through its full range of motion to inspect all ball bearings and races.
7. 7

   Mark and disassemble CV joint (if required for boot installation)
   Some outer CV boots can be installed without full joint disassembly by flexing the joint to maximum angle. If your boot kit requires full disassembly, use a marker to mark the orientation of the outer race to the inner race. Remove the snap ring from the shaft groove, then tap the outer race off the shaft with a brass drift and hammer. Keep all components in order.
8. 8

   Install new outer CV boot onto shaft
   Slide the new boot onto the shaft from the outer end, along with both new clamps (small clamp first, then large clamp, both loose). If you disassembled the joint, slide the boot into position on the shaft before reassembling. If installing without disassembly, work the boot over the joint carefully.
9. 9

   Reassemble and pack CV joint with grease
   If disassembled, reinstall the outer CV joint race onto the shaft aligning your previous marks, and install a new snap ring in the shaft groove. Pack the entire CV joint cavity with the grease provided in the boot kit, distributing it evenly into all areas of the joint. Work the grease into the ball races by rotating and flexing the joint. Pack approximately half the grease into the joint and the other half into the boot itself.
10. 10

    Position and secure CV boot
    Position the boot over the CV joint, ensuring it seats fully in both the shaft groove and the outer race groove. The boot should not be twisted. Equalize the air pressure by carefully lifting the thin edge of the boot with a blunt tool to allow trapped air to escape, then reseat. Install the small clamp on the shaft end and secure it tightly using a CV boot clamp tool. Install the large clamp on the joint housing end and secure it tightly.
11. 11

    Reinstall halfshaft into vehicle
    Guide the halfshaft assembly back through the hub area. Align the inner CV joint flange with the differential output flange and start all 6 bolts by hand. Torque the bolts to specification in a crossing pattern. Push the outer end of the halfshaft through the hub, aligning the splines.
    Torque spec

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

    Install new axle nut
    Install the new axle nut onto the end of the halfshaft and thread it by hand until seated. If a central axle nut is present (verify against the factory service manual), tighten it to the manufacturer-specified torque. Do not assume a generic value. If equipped with a cotter pin hole, align the nut castellations with the hole and install a new cotter pin, spreading the ends. If equipped with a staked nut design, use a punch to stake the nut collar into the shaft groove.
    ⚠Do not reuse the old axle nut. The locking feature may not function properly on subsequent installations.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel onto the hub, threading all lug nuts by hand. Tighten the lug nuts in a star pattern snug but not to final torque. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque the lug nuts to the manufacturer-specified value (verify against the factory service manual, approximately 100 lb-ft) in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all clamps on the CV boot are fully tightened and the boot is not twisted or kinked
2. Verify the axle nut is torqued to specification and properly secured with a new cotter pin or staked collar
3. Check differential fluid level through the fill plug and top off with 75W-140 synthetic GL-5 if any fluid was lost during halfshaft removal

Verification

• Start the vehicle and verify no unusual vibrations or noises from the rear differential or halfshaft
• Test drive the vehicle at various speeds and listen for clicking or popping noises during turns, which would indicate CV joint damage
• Visually inspect the new outer CV boot for any signs of leaking grease or improper seating after the test drive
• Recheck wheel lug nut torque after 50-100 miles of driving

More procedures for this vehicle