This procedure covers replacement of the inner CV boot on a 2012-2018 Jeep Wrangler JK with 3.6L V6 engine, requiring removal of the front axle shaft and disassembly of the inner CV joint.

Warnings

Tools required

Parts

• Inner CV boot kit (includes boot, clamps, grease) × 1 — Use OEM specification or equivalent for Dana 30/44 front axle
• Axle nut (replacement required) × 1 — Use OEM specification
• CV grease (if not included in boot kit) × 1 — Moly-based CV joint grease

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheel on side being serviced
6. Place drain pan under work area to catch any residual differential fluid

Procedure

1. 1

   Remove axle nut staking and nut
   Use a center punch and hammer to carefully collapse the staked portion of the axle nut away from the axle shaft groove. Use a breaker bar and appropriate socket to remove the axle nut. This nut is torqued to 281 Nm and will require significant force. Discard the nut as it cannot be reused.
2. 2

   Disconnect outer CV joint from steering knuckle
   Remove the bolts securing the outer CV joint flange to the steering knuckle hub assembly. There are typically 6 bolts. Once removed, pull the axle shaft outward slightly to disengage it from the hub splines.
   Torque spec

   CV Joint Bolts71 Nm (52 lb-ft)
3. 3

   Remove inner CV joint from differential
   If equipped with bolted inner CV joint: Remove the bolts connecting the inner CV joint to the front differential output flange. If equipped with plunge-type CV joint: Use a pry bar or CV joint separator to carefully separate the inner CV joint from the differential. Pull the entire axle shaft assembly out from under the vehicle.
   ⚠Some differential fluid may drain from the output seal. Keep drain pan positioned to catch fluid.
   Torque spec

   CV Bolts70 Nm (52 lb-ft)
4. 4

   Remove outer boot clamps and mark joint orientation
   Place the axle shaft on a clean work surface. Before disassembly, use a marker or punch to mark the relationship between the inner CV joint housing and the axle shaft. Cut and remove both boot clamps (large and small) from the inner CV boot using boot clamp pliers or side cutters.
5. 5

   Disassemble inner CV joint
   Slide the old boot away from the joint. Remove the snap ring or retaining clip that secures the CV joint housing to the tripod bearing assembly. Slide the CV joint housing off the tripod. Remove the second snap ring that retains the tripod bearing to the axle shaft. Mark the orientation of the tripod on the shaft, then carefully tap the tripod off using a brass drift or plastic mallet. Remove the old boot completely from the shaft.
   ℹ️Keep all bearings and rollers together with their respective races. Do not mix components if servicing both sides.
6. 6

   Clean and inspect components
   Thoroughly clean the axle shaft splines, CV joint housing, and tripod assembly using solvent and shop rags. Inspect all components for wear, pitting, or damage. Check the tripod bearings for smooth rotation and the CV joint housing for wear grooves. Replace the entire CV joint assembly if any component shows excessive wear.
7. 7

   Install new boot and tripod assembly
   Slide the new inner CV boot onto the axle shaft with the small end toward the center of the shaft. Install the tripod bearing assembly onto the shaft in the same orientation as marked during disassembly. The tripod may require light tapping with a plastic mallet. Install the retaining snap ring into the groove on the axle shaft to secure the tripod.
8. 8

   Pack CV joint with grease and assemble
   Pack approximately half of the supplied CV grease into the CV joint housing. Install the housing over the tripod assembly, aligning the marks made during disassembly. Pack the remaining grease around the tripod and into the boot. Install the outer snap ring or retaining clip to secure the housing to the tripod assembly.
   ℹ️Use all grease supplied in the boot kit. Proper lubrication is critical for CV joint longevity.
9. 9

   Position and secure boot clamps
   Slide the boot fully onto both the axle shaft and CV joint housing, ensuring it seats properly in the grooves on both ends. Check that the boot is not twisted. Install the small boot clamp on the axle shaft end and crimp securely using boot clamp pliers. Install the large boot clamp on the housing end and crimp securely. Ensure both clamps are tight and properly seated.
10. 10

    Reinstall axle shaft to differential
    Guide the axle shaft assembly back into position under the vehicle. Align the inner CV joint with the differential output. For bolted type: align the bolt holes and install bolts finger-tight. For plunge type: push the CV joint firmly into the differential until the retaining clip engages with a click. Verify the joint is fully seated.
    Torque spec

    CV Bolts70 Nm (52 lb-ft)
11. 11

    Connect outer CV joint to hub
    Align the outer CV joint flange with the hub assembly, ensuring the splines engage properly. Install the CV joint bolts and tighten to specification in a crisscross pattern.
    Torque spec

    CV Joint Bolts71 Nm (52 lb-ft)
12. 12

    Install new axle nut and stake
    Install the new axle nut onto the axle shaft threads. Torque the nut to specification. Using a center punch and hammer, stake the nut collar into the groove on the axle shaft to lock it in place. The staking should deform the nut material into the shaft groove.
    ℹ️Staking must be performed correctly to prevent nut loosening. The nut should not rotate after staking.
    Torque spec

    Axle Nut281 Nm (207 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Install the wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Double-check that all CV joint bolts are torqued to specification
2. Verify the axle nut is properly staked and cannot rotate
3. Check differential fluid level if significant fluid was lost during inner CV joint removal; top off with Mopar 75W-140 Synthetic Gear Lubricant if necessary
4. Inspect the work area for any tools or parts left behind

Verification

• Start the engine and verify no unusual noises from the front axle
• Turn the steering wheel lock-to-lock while stationary to check for binding or clicking
• Test drive the vehicle at low speed, making several turns in both directions to verify smooth CV joint operation
• Listen for any clicking, popping, or grinding noises during turns which would indicate improper assembly
• After test drive, inspect the new boot for any signs of grease leakage or damage
• Re-check axle nut staking and all fastener torques after test drive

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