CV Boot - Inner

Replace the inner CV boot on the halfshaft of a 2008 Dodge Viper, requiring removal of the halfshaft from the vehicle and disassembly of the inner CV joint.

Warnings

Tools required

Parts

• Inner CV boot kit (includes boot, clamps, and grease) × 1 — Use OEM specification
• Axle nut (single-use, do not reuse) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind the opposite end wheels
3. Loosen the wheel lug nuts while vehicle is still on the ground
4. Loosen (but do not remove) the 32mm axle nut while vehicle is on the ground with brakes applied or with an assistant holding the brake pedal
5. Raise the vehicle and support securely on jack stands at the manufacturer-specified jacking points
6. Remove the wheel and tire assembly
7. Place drain pan under the work area to catch any residual differential fluid

Procedure

1. 1

   Remove axle nut and separate lower ball joint
   Remove the 32mm axle nut completely (it was loosened during preparation). Remove the cotter pin from the lower ball joint castle nut. Remove the castle nut from the lower ball joint. Use a ball joint separator or pickle fork to separate the lower ball joint from the control arm. Apply force carefully to avoid damaging the ball joint boot if reusing the joint.
2. 2

   Remove halfshaft from differential
   Position a pry bar between the inner CV joint housing and the differential case. Pry the halfshaft assembly out of the differential with firm, controlled force. The inner CV joint is retained by a circlip on the stub shaft that will disengage as you pull. Once the splines disengage, support the halfshaft to prevent it from dropping. Pull the outer end of the halfshaft through the hub bearing to remove the entire assembly from the vehicle. Some differential fluid may drain out; this is normal.
3. 3

   Secure halfshaft and remove outer boot clamps
   Secure the halfshaft in a vise using soft jaws or with the outer CV joint supported on a workbench. If the outer boot will not be replaced, slide it away from the inner joint area to provide working clearance. Cut or release the large and small clamps on the inner CV boot using boot clamp pliers or side cutters. Slide the damaged boot away from the inner CV joint housing toward the center of the shaft to expose the joint.
4. 4

   Mark and disassemble inner CV joint
   Wipe away excess grease from the tripod housing and shaft. Use a paint marker or scribe to mark the orientation of the tripod assembly relative to the shaft splines (mark one spider leg and the corresponding shaft position). Remove the circlip or snap ring that retains the tripod assembly on the shaft using snap ring pliers. The tripod assembly consists of a spider with three trunnions and roller bearings. Slide the tripod housing off the tripod assembly. Use a brass punch and hammer or a bearing puller to carefully remove the tripod assembly from the shaft, tapping evenly around the spider to avoid cocking it on the splines. Keep all needle bearings and rollers organized if they separate.
5. 5

   Remove old boot and clean components
   Slide the damaged inner CV boot completely off the shaft. Thoroughly clean the shaft splines, tripod assembly, inner housing, and all CV joint components using degreaser and shop rags. Inspect the tripod rollers, needle bearings, trunnions, and inner housing races for wear, pitting, or damage. Any significant wear requires replacement of the entire joint assembly, not just the boot. Inspect the shaft splines for damage or wear.
6. 6

   Install new boot and clamps
   Slide the small boot clamp onto the shaft, followed by the new inner CV boot (small end first). Position the small end of the boot in the groove on the shaft. Install the small clamp in the boot groove but do not tighten yet. Ensure the boot is seated properly in the shaft groove with no twists or folds.
7. 7

   Reinstall tripod assembly
   Align the tripod assembly with the shaft splines according to the orientation marks made during disassembly. Slide or tap the tripod assembly onto the shaft until it is fully seated. Install the retaining circlip or snap ring in the shaft groove using snap ring pliers. Verify the circlip is fully seated in its groove and the tripod cannot be pulled off the shaft.
8. 8

   Pack joint with grease and install housing
   Pack the supplied grease from the CV boot kit into the tripod housing, filling approximately half of the housing volume. Pack additional grease into the tripod roller assembly and around the trunnions. Slide the tripod housing over the tripod assembly, ensuring the rollers engage properly in the housing races. Distribute the grease evenly by rotating the housing through its range of motion.
9. 9

   Seat boot and install large clamp
   Slide the large end of the boot over the inner CV joint housing and seat it in the housing groove. Ensure the boot is not twisted. Equalize air pressure in the boot by inserting a small flat blade between the boot and housing briefly, then remove. Position the large boot clamp in the boot groove on the housing. Using the boot clamp crimping tool, crimp the large clamp securely. Tighten the small clamp on the shaft end using the crimping tool.
10. 10

    Inspect differential seal and prepare for installation
    Before reinstalling the halfshaft, inspect the differential output seal for leaks or damage. If the seal shows wear or leakage, replace it now while the halfshaft is removed. Clean the differential stub shaft splines and the area around the seal. Verify the circlip on the inner CV joint stub shaft is present and in good condition; replace if damaged.
11. 11

    Reinstall halfshaft into differential
    Align the inner CV joint stub shaft with the differential output splines. Push the halfshaft firmly into the differential until the circlip engages with an audible click or firm resistance. Tug on the inner joint housing to confirm the circlip has engaged and the halfshaft is retained. Insert the outer end of the halfshaft through the hub bearing, aligning the splines with the hub.
12. 12

    Reconnect lower ball joint and install axle nut
    Reconnect the lower ball joint to the control arm. Install the castle nut and torque to specification (specification not available in database; consult factory service manual). Install a new cotter pin through the castle nut and bend the ends to secure. Thread the new 32mm axle nut onto the halfshaft by hand, then snug it with a socket but do not torque yet (final torque must be done with vehicle on the ground).
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the wheel and tire assembly. Thread the lug nuts by hand, then snug them in a star pattern. Lower the vehicle until the tire just contacts the ground but the suspension is not fully loaded. Torque the lug nuts to specification in a star pattern. Lower the vehicle completely to the ground.
14. 14

    Final torque axle nut
    With the vehicle on the ground and the parking brake applied (or an assistant holding the brake pedal), torque the axle nut to specification using a torque wrench and breaker bar (specification not available in database; consult factory service manual for the exact value). Verify the nut is fully torqued and seated.

Reassembly

1. Reassembly is covered in the procedural steps above, following the reverse order of disassembly
2. Always use a new axle nut; do not reuse the old one
3. Ensure all circlips and snap rings are fully seated in their grooves
4. Verify the inner CV joint is firmly retained in the differential by attempting to pull it out after installation

Verification

• Start the engine and slowly drive the vehicle forward and backward a short distance, listening for clicking, popping, or grinding noises from the CV joint area
• Turn the steering wheel to full lock in both directions while driving slowly; the CV joint should operate smoothly without binding or noise
• Inspect the new inner CV boot for proper seating, no twists, and secure clamps
• Check for any differential fluid leaks around the output seal
• Verify the axle nut is torqued to specification and the lower ball joint castle nut has a properly installed cotter pin

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