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CV Boot - Inner: Installation: Notes

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
  1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then, slide the replacement inner tripod joint sealing boot onto the interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. See  Fig 1 . 
    Fig 1: Sealing Boot Installation on Interconnecting Shaft
    GC0000048Courtesy of DAIMLERCHRYSLER CORP.
    1 - SEALING BOOT
    2 - RAISED BEAD IN THIS AREA OF SEALING BOOT
    3 - GROOVE
    4 - INTERCONNECTING SHAFT
  2. Install spider assembly onto interconnecting shaft. See Fig 2. Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift. See Fig 3. Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. 
    Fig 2: Spider Assembly Installation on Interconnecting Shaft
    GC0000049Courtesy of DAIMLERCHRYSLER CORP.
    1 - SPIDER ASSEMBLY
    2 - INTERCONNECTING SHAFT
    Fig 3: Installing Spider Assembly on Interconnecting Shaft
    GC0000050Courtesy of DAIMLERCHRYSLER CORP.
    1 - DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER ASSEMBLY
    2 - SPIDER ASSEMBLY
    3 - INTERCONNECTING SHAFT
    4 - BRASS DRIFT
  3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of interconnecting shaft. See Fig 4. Be sure the snap ring is fully seated into groove on interconnecting shaft.
    Fig 4: Spider Assembly Retaining Snap-Ring
    GC0000046Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERCONNECTING SHAFT
    2 - SPIDER ASSEMBLY
    3 - RETAINING SNAP RING
  4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot.
  5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft. See Fig 5.
    Fig 5: Removing/Installing Tripod Housing at Spider Assembly
    GC0000045Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRIPOD JOINT HOUSING
    2 - SPIDER ASSEMBLY
    3 - SEALING BOOT
  6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot.
  7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. See Fig 6. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. See Fig 7.
    Fig 6: Crimping Tool Installed on Sealing Boot Clamp - Typical
    GC0000051Courtesy of DAIMLERCHRYSLER CORP.
    1 - SPECIAL TOOL C-4975A
    2 - INTERCONNECTING SHAFT
    3 - CLAMP
    4 - SEALING BOOT
    Fig 7: Sealing Boot Retaining Clamp Installed - Typical
    GC0000052Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLAMP
    2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE
    3 - INTERCONNECTING SHAFT
    4 - SEALING BOOT
    CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand.
  8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot.
    CAUTION: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing sealing boot durability can be adversely affected.
    CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot can not be used.
  9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly. See Fig 8. When inserting trim stick between tripod housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing. If this is not done damage to the sealing boot can occur.  If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing not the hard plastic sealing boot and soft rubber insert.
    Fig 8: Trim Stick Inserted for Venting CV Joint
    GC0000053Courtesy of DAIMLERCHRYSLER CORP.
    1 - INNER TRIPOD JOINT SEALING BOOT
    2 - SEALING BOOT CLAMP
    3 - INNER TRIPOD JOINT HOUSING
    4 - TRIM STICK
  10. With trim stick inserted between sealing boot and tripod joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint housing. This procedure will equalize the air pressure in the tripod joint, preventing premature sealing boot failure. 
  11. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recess's of the tripod housing.
  12. Clamp tripod joint sealing boot to tripod joint, using required procedure for type of boot clamp application.
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