CV Boot - Outer

Replace the outer CV boot on the front axle half-shaft to prevent dirt and moisture contamination of the CV joint.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps and grease × 1 — Use OEM specification
• Lower ball joint cotter pin × 1 — Use OEM specification
• Hub nut × 1 — Use OEM specification - typically single-use

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 (do not remove)
4. Loosen but do not remove the front axle hub nut while vehicle is on ground - this nut is extremely tight
5. Raise front of vehicle and support securely on jack stands at frame rails
6. Remove front wheel on the side being serviced

Procedure

1. 1

   Remove hub nut and brake caliper
   Remove the front axle hub nut completely and set aside (should be replaced with new). Remove the two brake caliper mounting bolts and hang the caliper from the suspension with wire or a bungee cord - do not let it hang by the brake hose. Remove the brake rotor.
2. 2

   Disconnect lower ball joint
   Remove the cotter pin from the lower ball joint castle nut. Remove the castle nut. Use a ball joint separator or pickle fork to separate the lower ball joint from the steering knuckle. Be careful not to damage the ball joint boot if reusing the ball joint.
3. 3

   Disconnect tie rod end
   Remove the cotter pin and castle nut from the tie rod end. Use a ball joint separator or pickle fork to separate the tie rod end from the steering knuckle. This provides additional clearance to pull the axle shaft outward.
4. 4

   Remove axle shaft from hub
   Pull the steering knuckle and hub assembly outward while carefully pulling the axle shaft out of the hub splines. You may need to tap the end of the shaft with a soft mallet if it is stuck. Support the axle shaft - do not let it hang freely or overextend the inner CV joint.
5. 5

   Remove damaged outer CV boot
   Cut off the old boot clamps using side cutters or clamp pliers. Slide the damaged boot off the CV joint toward the center of the shaft. Wipe away all old grease from the CV joint using clean rags. Inspect the CV joint for damage, wear, or pitting - if the joint itself is damaged, the entire shaft should be replaced.
6. 6

   Clean CV joint and shaft
   Thoroughly clean the outer CV joint housing, balls, and cage with solvent and rags to remove all old grease and contaminants. Use a wire brush if necessary. Clean the shaft surface where the boot will seat. Inspect all components for wear or damage. Rotate the joint and verify smooth operation without binding.
7. 7

   Install new boot and clamps
   Slide the new small boot clamp onto the axle shaft, followed by the new 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 CV boot clamp tool - ensure it is properly seated and tight.
8. 8

   Pack CV joint with grease
   Pack the CV joint with the grease supplied in the boot kit. Work grease into all areas of the joint, between the balls and cage. Fill the boot approximately half full with the remaining grease - do not overfill as this can cause the boot to burst. Ensure all grease from the kit is used.
9. 9

   Secure outer boot clamp
   Slide the large end of the boot over the CV joint housing and seat it in the housing groove. Before tightening, ensure the boot is not twisted and there is no excess air trapped - you may need to burp the boot by carefully lifting the edge. Install the large clamp and tighten securely with the clamp tool.
10. 10

    Reinstall axle shaft into hub
    Carefully guide the axle shaft back through the hub splines, supporting the shaft to avoid overextending the inner joint. Push the shaft fully into the hub until seated. Install the hub nut finger-tight only at this stage.
11. 11

    Reconnect tie rod and ball joint
    Reconnect the tie rod end to the steering knuckle and install the castle nut. Tighten to specification and install a new cotter pin. Reconnect the lower ball joint to the knuckle, install the castle nut, tighten to specification, and install a new cotter pin.
12. 12

    Reinstall brake components and wheel
    Reinstall the brake rotor. Mount the brake caliper back in position and install the mounting bolts to specification. Install the wheel and thread the lug nuts on finger-tight.
13. 13

    Torque hub nut and wheel
    Lower the vehicle until the tire just contacts the ground (weight not fully on tire). Torque the axle nut to the factory specification for the 2007 Ram 3500 Dana 60 front hub - consult the factory service manual for the exact value. Stake or install cotter pin if applicable to your hub nut design. Lower vehicle completely and torque wheel lug nuts to specification in a star pattern.

Reassembly

1. Torque specifications not provided in database - consult factory service manual for hub nut (typically 185-250 ft-lbs), wheel lug nuts (135 ft-lbs typical), brake caliper bolts, and ball joint nuts
2. Always use a new hub nut if specified by manufacturer as single-use
3. Ensure all cotter pins are properly installed and bent to prevent loosening
4. Boot clamps must be tight enough to prevent grease leakage but not so tight they cut the boot material

Verification

• Inspect the CV boot for proper seating in both grooves with no twists or folds
• Check that boot clamps are properly tightened and secure
• Verify no grease is leaking from the boot
• Test drive the vehicle and listen for any clicking or popping sounds from the CV joint during turning
• After test drive, re-inspect the boot for any signs of leakage or movement
• Verify steering operates normally with no binding or unusual noises

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