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CV Boot - Outer: Installation

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 new sealing boot to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer C/V joint assembly sealing boot onto the interconnecting shaft. See Fig 1. 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. 
    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. Align splines on interconnecting shaft with splines on cross of outer C/V joint assembly and start outer C/V joint onto interconnecting shaft.
  3. Install outer C/V joint assembly onto interconnecting shaft by using a soft-faced   hammer and tapping end of stub axle (with nut installed) until outer C/V joint is fully seated on interconnecting shaft. See Fig 2.
    Fig 2: Outer C/V
    GC0031129Courtesy of DAIMLERCHRYSLER CORP.
    1 - SOFT FACED HAMMER
    2 - STUB AXLE
    3 - OUTER C/V JOINT
    4 - NUT
  4. Outer C/V joint assembly must be installed on interconnecting shaft until cross of outer C/V joint assembly is seated against circlip on interconnecting shaft. See Fig 3.
    Fig 3: Outer C/V Joint Correctly Installed on Interconnecting Shaft
    GC0031130Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERCONNECTING SHAFT
    2 - CROSS
    3 - OUTER C/V JOINT ASSEMBLY
  5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer C/V joint assembly housing. Put the remaining amount into the sealing boot.
  6. Install outer C/V joint sealing 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 4. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. See Fig 5.
    Fig 4: 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 5: 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 outer C/V joint sealing boot into its retaining groove on outer C/V joint housing. Install sealing boot to outer C/V joint retaining clamp evenly on sealing boot.
  9. Clamp sealing boot onto outer C/V joint housing 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
GC0000054Courtesy of DAIMLERCHRYSLER CORP.
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975A
4 - SEALING BOOT
Fig 7: Sealing Boot Retaining Clamp Installed
GC0000055Courtesy of DAIMLERCHRYSLER CORP.
1 - CLAMP
2 - TRIPOD HOUSING
3 - SPECIAL TOOL C-4975A
4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE
5 - SEALING BOOT
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