Boot-CV Outer: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Sealing Boot Installation on Interconnecting Shaft

Courtesy of DAIMLERCHRYSLER CORP.

Slide new sealing boot (1) to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer C/V joint assembly sealing boot onto the interconnecting shaft. 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 2: Outer C/V Joint Installation on Interconnecting Shaft
Courtesy of DAIMLERCHRYSLER CORP.
Align splines on interconnecting shaft with splines on cross of outer C/V joint assembly and start outer C/V joint onto interconnecting shaft.
Install outer C/V joint assembly onto interconnecting shaft by using a soft-faced hammer (1) and tapping end of stub axle (with nut installed) until outer C/V joint is fully seated on interconnecting shaft.

Fig 3: Outer C/V Joint Correctly Installed on Interconnecting Shaft
Courtesy of DAIMLERCHRYSLER CORP.
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 (1).

Fig 4: Sealing Boot Retaining Clamp Installed
Courtesy of DAIMLERCHRYSLER CORP.
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.
Install outer C/V joint sealing boot to interconnecting shaft clamp evenly on sealing boot.
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. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (2).

Fig 5: Sealing Boot Retaining Clamp Installed
Courtesy of DAIMLERCHRYSLER CORP.

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.
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.
Clamp sealing boot onto outer C/V joint housing using Crimper, Special Tool C-4975-A (3) and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (2).