This procedure covers replacement of the outer CV boot on a 2015 Kia Forte 1.8L I4, including axle removal, boot replacement, and reinstallation with proper greasing and torque specifications.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps and grease × 1 — Use OEM specification or equivalent CV boot kit
• Axle nut (stake-type) × 1 — Use OEM specification - one-time use
• CV joint grease (if not included in kit) × 1 — Typically 100-120g included in boot kit

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. With vehicle on ground and brake applied, loosen axle nut using breaker bar and 32mm socket (do not remove yet)
4. Loosen wheel lug nuts while vehicle is on ground
5. Raise front of vehicle and support securely on jack stands at manufacturer frame points
6. Remove wheel completely
7. Position drain pan under transmission area to catch any fluid spillage

Procedure

1. 1

   Remove axle nut and disconnect steering knuckle
   Remove the previously loosened axle nut completely. If the outer CV joint has bolts connecting to the intermediate shaft, skip to step 2. For this Forte configuration, the outer end remains in the wheel hub during removal.
2. 2

   Separate axle from hub
   Using a pry bar or CV joint spreader tool, carefully press the axle shaft out of the wheel hub assembly. You may need to tap the end of the shaft with a dead blow hammer while supporting the axle. Do not allow the axle to hang freely as this can damage the inner CV joint.
3. 3

   Remove axle assembly from vehicle
   Carefully pry the inner CV joint from the transmission using a pry bar positioned between the inner joint housing and transmission case. Pull the axle assembly straight out. Some transmission fluid may drain - this is normal. Support the axle and place it on a clean work surface.
   ⚠Avoid damaging the transmission seal when prying out the inner CV joint. Use a suitable pry point on the CV joint housing, not the boot or shaft.
4. 4

   Remove outer CV boot clamps
   With the axle on the workbench, use wire cutters or boot clamp pliers to remove both clamps from the outer CV boot (large and small clamps). Cut or release the clamps and slide them off the boot.
5. 5

   Separate outer CV joint from axle shaft
   Slide the damaged boot toward the inner joint to expose the outer CV joint. Locate the snap ring or circlip inside the outer CV joint. Using snap ring pliers, remove the retaining ring. Mark the orientation of the CV joint to the shaft with a paint marker. Using a brass drift or dead blow hammer, strike the inner race of the CV joint sharply to separate it from the axle shaft splines. Remove old boot completely.
6. 6

   Clean and inspect components
   Thoroughly clean the axle shaft splines and CV joint splines using a wire brush and clean shop rags. Inspect the CV joint for wear, pitting, or damage. Check that all bearing balls are present and rollers move smoothly. If the joint is damaged or shows excessive wear, the entire CV joint must be replaced. Clean old grease from the joint housing.
7. 7

   Install new outer CV boot
   Slide the new small boot clamp onto the axle shaft, followed by the new CV boot (small end first). Ensure the boot is positioned correctly on the shaft with the small end seating groove aligned with the boot installation mark on the shaft.
8. 8

   Reinstall outer CV joint
   Pack the CV joint housing with the supplied CV grease (typically half the grease goes in the housing, half in the boot). Align the marks made during disassembly and slide the CV joint onto the axle shaft splines. Tap firmly with a dead blow hammer until the joint seats fully. Install the new snap ring or circlip to secure the joint, ensuring it seats completely in its groove.
9. 9

   Complete boot installation
   Add the remaining CV grease into the boot. Slide the large end of the boot over the CV joint housing, ensuring it seats properly in the housing groove. The boot should not be twisted. Position the small clamp on the shaft groove and secure it tightly using boot clamp pliers. Position the large clamp on the housing groove and secure it. Ensure the boot is not stretched or compressed - adjust axle length if necessary by extending or compressing slightly before final clamp tightening.
10. 10

    Reinstall axle assembly
    Carefully insert the inner CV joint into the transmission, aligning the splines. Push firmly until the circlip clicks into place inside the transmission. Insert the outer CV joint stub shaft into the wheel hub, ensuring proper spline engagement. Install the new axle nut and thread it on by hand.
11. 11

    Torque axle nut and reinstall wheel
    Install the wheel and hand-tighten lug nuts. Lower the vehicle until the tire just touches the ground (enough to prevent rotation). Using a torque wrench, torque the axle nut to specification. Stake the axle nut collar into the shaft groove using a punch and hammer, or install a new cotter pin if applicable to your specific axle design. Finish lowering the vehicle to the ground.
    ⚠The axle nut must be properly staked or pinned after torquing to prevent it from loosening during operation.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
12. 12

    Final wheel torque
    With the vehicle on the ground, torque the wheel lug nuts to specification in a star pattern to ensure even pressure distribution.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Check transmission fluid level and top off if necessary with Kia SP-IV-M ATF
2. Test drive the vehicle at low speed and verify no clicking, popping, or vibration from the CV joint
3. Recheck wheel lug nut torque after 50-100 miles of driving

Verification

• Verify axle nut is properly torqued and staked/pinned
• Inspect CV boot for proper seating with no twists or damage
• Check for transmission fluid leaks around the inner CV joint seal
• Turn steering wheel lock-to-lock while stationary and verify no binding
• Test drive and listen for clicking or popping noises during turns, which would indicate improper installation or damaged CV joint
• Verify no vibration at highway speeds

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