Replace the inner CV boot on the front axle shaft by removing the axle from the vehicle, disassembling the inner joint, installing a new boot and clamp, repacking with grease, and reinstalling.

Warnings

Tools required

Parts

• Inner CV boot kit with clamps × 1 — Use OEM specification
• CV joint grease (typically included in boot kit) × 1 — Use grease included with boot kit
• Axle nut (if not staked type) × 1 — Use OEM specification
• 75W-90 GL-5 Gear Oil (if differential seal disturbed) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. With vehicle in park and brake applied, loosen but do not remove the 32mm axle nut using breaker bar
5. Raise front of vehicle and support securely on jack stands at manufacturer-recommended lift points
6. Remove wheel completely
7. Place drain pan under work area to catch any gear oil that may escape

Procedure

1. 1

   Remove axle nut and disconnect outer end
   Remove the 32mm axle nut completely and set aside (this nut should be replaced). Remove the wheel speed sensor connector if it interferes with axle removal. Do not allow the axle to fall or hang unsupported.
2. 2

   Disconnect inner CV joint from differential
   Locate the six CV bolts securing the inner joint to the differential output flange. Remove all six bolts using a 12mm socket. Support the axle shaft to prevent it from falling. Carefully pull the inner joint assembly away from the differential flange.
   Torque spec

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

   Remove axle shaft from vehicle
   Carefully pull the outer end of the axle shaft out of the hub assembly. You may need to tap the end with a soft-faced hammer or use a puller if the shaft is stuck in the hub splines. Once free, remove the entire axle shaft from the vehicle and place on a clean work surface. Keep the shaft horizontal to prevent the outer CV joint from separating.
4. 4

   Remove old inner CV boot and clamps
   Cut and remove the old boot clamps from both the large and small ends of the inner CV boot using clamp pliers or side cutters. Slide the old boot toward the center of the shaft to expose the inner CV joint. Wipe away old grease with clean rags to expose the joint mechanism.
5. 5

   Disassemble inner CV joint
   The inner joint uses a tripod design. Remove the snap ring securing the tripod to the axle shaft using snap ring pliers. Mark the orientation of the tripod on the shaft before removal. Slide the tripod assembly off the shaft (it may require tapping with a soft hammer). Remove the outer housing from the tripod. Remove the old boot completely from the shaft.
6. 6

   Clean axle shaft and inspect components
   Thoroughly clean the axle shaft where the boot will seal using a wire brush and clean rags. Remove all old grease from the shaft, tripod, and housing. Inspect the tripod bearings for wear, pitting, or damage. Inspect the housing inner race for scoring or wear. Replace the entire CV joint if any damage is found.
7. 7

   Install new inner CV boot
   Slide the new small boot clamp onto the axle shaft, followed by the new inner CV boot (small end first). Position the small end of the boot in the groove on the axle shaft. Install and tighten the small clamp using the boot clamp tool, ensuring the boot is properly seated in its groove.
8. 8

   Reassemble tripod joint
   Slide the tripod assembly back onto the axle shaft in the exact orientation marked during disassembly (the tripod is directional). Install the snap ring to secure the tripod to the shaft, ensuring it is fully seated in its groove. Pack the tripod with approximately half of the CV grease provided in the boot kit.
9. 9

   Complete CV joint assembly
   Pack the remaining CV grease into the outer housing. Install the housing over the tripod assembly, ensuring the tripod rollers engage properly with the housing tracks. Slide the large end of the boot over the housing and position it in the housing groove. Ensure the boot is not twisted or stretched.
10. 10

    Secure large boot clamp
    Before installing the large clamp, equalize air pressure in the boot by inserting a small flat tool between the boot and housing to allow trapped air to escape. Remove the tool and install the large clamp over the boot. Tighten the large clamp securely using the boot clamp tool, ensuring the boot remains properly seated in the housing groove.
11. 11

    Reinstall axle shaft in vehicle
    Carefully guide the outer end of the axle shaft back into the hub assembly, ensuring the splines engage properly. Support the inner end and align the inner CV joint with the differential output flange. Install all six CV bolts finger-tight initially.
12. 12

    Torque CV bolts and axle nut
    Torque the six CV bolts to specification in a star pattern to ensure even seating. Install a new axle nut onto the axle shaft end and torque to specification. Stake the nut or install a new cotter pin as per the original design (most 2016-2024 Tucsons use a staked nut).
    Torque spec

    CV Bolts61 Nm (45 lb-ft)

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

    Reinstall wheel and lower vehicle
    Reinstall the wheel and hand-tighten all lug nuts. Lower the vehicle until the tire just contacts the ground (but weight is still on jack stands). Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reconnect any wheel speed sensor connectors that were disconnected
2. Check front differential fluid level if any leakage occurred during axle removal and top off with 75W-90 GL-5 gear oil if necessary
3. Verify axle nut is properly staked or secured with cotter pin

Verification

• Test drive the vehicle and listen for any clicking, popping, or vibration from the front axle during turns and acceleration
• Visually inspect the new inner CV boot for any tears, proper seating, and secure clamps
• Check for any gear oil leaks around the differential output flange
• Verify smooth operation through full steering range in both directions
• Recheck axle nut torque after 50-100 miles of driving

More procedures for this vehicle