DIY Network

Axle CV-Boot Joint -- Parts Installation and Reassembly From "Weekend Mechanic" episode WKM-201

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Figure A Figure B Figure C Figure D Figure E Figure F Figure G Figure H Figure I Figure J Figure K Figure L Figure M Figure N Figure O Figure P Figure Q Figure R Figure S Figure T Figure U

Boot Kit Installation and Axle Replacement

The final steps in the project are the installation of the new boot kit and re-installation of the repaired and the new axles onto the vehicle.

Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular car or truck, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools.

• Brake cleaner was used as a solvent to clean the parts prior to re-assembly ( figure A). After cleaning, it's critical to remove all of the solvent from the parts to avoid contaminating the new grease that will be applied.

  
  

• With the parts disassembled, the outboard tulip joint can be inspected closely to see how it works (figure B). This joint allows the axle to have the range of motion needed to adjust the suspension to different road conditions while driving.

  
  

• Before installing the new boot, this outboard joint must be packed and lubricated. Stand the axle up and apply grease to the joint (figure C). Remember that the tulip joint requires the heavy-duty grease. Use about half of the tube of heavy-duty grease in the joint itself.

  
  

• With the grease applied, work the joint to ensure that the component is well coated.

  
  

• Next, install the outboard boot by sliding it over the axle shaft until it fits into the groove on the housing (figure D).

  
  

• Apply the remainder of the heavy-duty grease in the boot itself (figure E).

  
  

• Clean any excess grease off of the edges of the boot, where the clamps will be installed, so that there's no chance of their slipping.

  
  

• Install the clamps to secure the boot. For the larger outboard clamp, simply slide the clamp into position, making sure that it fits into the groove, and bend the tabs down (figure F). Tap the tab with a hammer -- or use a crimping tool -- to make sure that the clamp is secure.

  
  

• Secure the smaller, inboard clamp in the same manner (figure G).

  Tip: When installing the smaller clamp, rotate it so that the tab is facing 180 degrees from the tab on the larger clamp. Aligning the tabs on opposite sides in this manner helps to weight-balance the axle.

  
  

• The longer of the two boots is installed on the inboard joint. Place the small clamp on the axle-shaft, then install the boot. Secure the boot with the small clamp (figure H). The boot fits tightly onto the shaft, but avoid lubricating them. The shaft needs to be dry for the clamp to provide a secure hold.

  
  

• Install the tripod joint onto the shaft, making sure to line up the reference marks that were made earlier (figure I).

  
  

• Using snap-wring pliers, pop a new snap-clip into the groove on the end of the axle to hold the joint secure (figure J).

  
  

• Apply the lighter-weight axle grease to the inboard joint (figure K)

  
  

• Using your fingers to spread the grease on, fully lubricating the joint (figure L).

  
  

• Use half of the remaining grease to pack the housing, and the remainder in the boot itself.

  
  

• Once the grease has all been applied thoroughly, use a rag to wipe the edges of the housing clean (figure M) so that the clamp won't slip.

  
  

• Slide the large clamp onto the shaft. Then use the seam of the boot as a reference mark, and line it up with the mark you made earlier on the shaft with the punch. Find the reference mark on the housing, and match it up with the boot seam to align and install the housing onto the joint (figure N).

  
  

• Secure the boot using the small and large clamps (figure O), just as was done earlier with the outboard boot. As before, make sure that the tabs are aligned 180 degrees from each other for proper weight-balancing.

  
  

• With both boots installed, the axle is complete and ready to install on the vehicle (figure P).

  
  

• The installation of the refurbished axle, as well as the new axle (figure Q) is the reverse of the removal procedure done earlier. Feed the axle through the control arm, and line it up with the spindle.

  
  

• Align the inboard plate with the differential flange (figure R), and install the nuts.

  
  

• With the stabilizer links tightened in position, proceed to the outside of the axle. First, install the spacer (figure S).

  
  

• Then, using snap-ring pliers, install the snap-ring (figure T), making certain that it seats fully into its groove.

  
  

• Re-install the hub-cover (figure U), making sure to follow the reference marks made earlier. Note that each bolt has three securing elements, installed in the following order: tapered spacer, washer and nut.

  
  

• With both axles installed, the wheels and tires can be put back on to complete the project.

Tip: Each time you rotate your tires or change your oil, inspect your CV-joints boots. Replacing a cracked or torn boot may save you from having to replace an axle shaft later.

RESOURCES :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896