CV Boot - Inner

This procedure covers removal and replacement of the inner CV boot on the front axle of a 2007 Ram 3500 with 5.9L Cummins diesel engine and 4WD.

Warnings

Tools required

Parts

• Inner CV boot kit with clamps × 1 — Verify fitment for Dana 60 or AAM 9.25 front axle
• CV joint grease × 1 — Usually included with boot kit
• Axle seal × 1 — Use OEM specification

Fluids

• 75W-90 synthetic gear oil — 3.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
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 the side requiring service
6. Place drain pan under front differential and remove fill plug, then drain plug to drain gear oil

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and hang the caliper with wire or a bungee cord to avoid stress on the brake line. Do not let it hang by the hose. Remove the brake rotor by pulling straight off the hub. If stuck, use penetrating oil and tap with a hammer.
2. 2

   Remove hub nut and ABS sensor
   Remove the front hub/bearing assembly retaining hardware and axle stub nut per factory specification for your axle type (verify size before starting). This nut is typically very tight and may require a breaker bar. Disconnect the ABS wheel speed sensor connector if equipped and remove the sensor mounting bolt to move it out of the way.
3. 3

   Separate tie rod end
   Remove the cotter pin and castle nut from the tie rod end. Use a pickle fork or tie rod separator tool to separate the tie rod end from the steering knuckle. Be careful not to damage the tie rod boot.
4. 4

   Remove upper ball joint
   Remove the upper ball joint mounting bolts or pinch bolt securing the upper ball joint to the steering knuckle, depending on your axle configuration. Support the knuckle assembly to prevent it from dropping.
5. 5

   Remove axle shaft from differential
   Using a pry bar positioned between the inner CV joint housing and the differential, carefully pry the axle shaft out of the differential. You may need to tap the pry bar with a hammer. The shaft should pop free from the internal snap ring or C-clip. Pull the entire axle shaft assembly out through the steering knuckle.
6. 6

   Remove outer CV boot clamps
   Place the axle shaft assembly on a clean work surface. Use side cutters or a clamp removal tool to cut and remove the clamps securing the inner CV boot. Note the orientation and position of the boot for reassembly.
7. 7

   Separate inner CV joint
   Slide the inner CV boot away from the joint to expose the internal components. Remove the snap ring or retaining clip holding the CV joint to the axle shaft. Mark the orientation of the joint housing to the shaft with a marker or scribe. Carefully pull or tap the CV joint housing off the shaft, taking care to catch any loose bearings or components.
8. 8

   Clean and inspect components
   Thoroughly clean the axle shaft, CV joint housing, and all CV joint components with solvent and rags. Inspect the CV joint for wear, pitting, or damage. Check the axle shaft splines for damage. Replace the entire CV joint if any wear is found, as a boot replacement alone will not fix a worn joint.
9. 9

   Install new inner CV boot
   Slide the new inner CV boot onto the axle shaft with the small end toward the center of the shaft. Ensure the boot is not twisted. Position the small boot clamp on the boot but do not tighten yet.
10. 10

    Reassemble CV joint
    Pack the CV joint housing with the supplied CV joint grease, distributing it evenly among the bearing races. Apply grease to the axle shaft splines and ball bearings. Align the marks made during disassembly and install the CV joint housing onto the axle shaft. Install the snap ring or retaining clip to secure the joint.
11. 11

    Secure CV boot and clamps
    Slide the boot over the CV joint housing and ensure it seats properly in the boot grooves on both the shaft and housing. Add any remaining grease from the kit into the boot. Position the large boot clamp. Using CV boot clamp pliers or a crimping tool, secure both the small and large clamps tightly. Ensure the boot is not twisted or stretched.
12. 12

    Install new differential seal
    Clean the differential seal bore with a wire brush and solvent. Using a seal driver or large socket, carefully tap the new axle seal into the differential housing until it is flush and fully seated. Lubricate the seal lip with gear oil. On a solid front axle, the seal in question is typically the axle tube inner seal, not necessarily a differential carrier seal. Install new axle shaft seal in the axle tube/differential per factory specification for your axle type.
13. 13

    Reinstall axle shaft assembly
    Carefully guide the axle shaft through the steering knuckle and align the inner CV joint splines with the differential side gear. Push the shaft firmly into the differential until the snap ring or C-clip seats with an audible click. Give the shaft a firm pull outward to verify it is locked in place.
14. 14

    Reassemble steering and suspension components
    Reconnect the upper ball joint to the steering knuckle and install the mounting bolts or pinch bolt. Reconnect the tie rod end to the steering knuckle and install the castle nut and new cotter pin. Install the hub/axle nut and torque to factory specification (verify exact value for your axle before assembly). Reconnect the ABS sensor and secure the mounting bolt.
15. 15

    Reinstall brake components and refill differential
    Reinstall the brake rotor and caliper, tightening the caliper mounting bolts securely. Reinstall the wheel and snug the lug nuts. Lower the vehicle and torque the lug nuts in a star pattern. Refill the front differential with the factory-specified quantity of 75W-90 gear oil (approximately 3.0 quarts for AAM 9.25, verify for your axle) through the fill hole until oil reaches the bottom of the fill plug opening. Install the fill plug.

Reassembly

1. Torque all fasteners to manufacturer specifications using a torque wrench
2. Ensure the CV boot is properly seated and clamps are secure with no gaps
3. Verify the axle shaft is fully engaged in the differential and cannot be pulled out
4. Check that the ABS sensor has adequate clearance and is not contacting rotating components

Verification

• Test drive the vehicle and listen for clicking or popping noises during turns, which would indicate CV joint issues
• Inspect the new CV boot for leaks or grease seepage after the test drive
• Verify no gear oil is leaking from the differential seal
• Check for proper operation of ABS system if equipped
• After 50-100 miles, recheck the differential fluid level and top off if necessary

More procedures for this vehicle