Outer Boot & CV Joint

1. Cut and remove boot clamps, then cut boot lengthwise and remove it from shaft.
2. Remove as much grease as possible from stub axle, starplate arm and spider and yoke. Use cloths to remove grease, do not use solvent.
3. Push stub axle inward to relieve thrust spring tension, then, using suitable screwdriver, carefully raise starplate arms one at a time, being careful not to twist arms.
4. Remove stub axle from yoke, then remove and retain stub axle thrust ball and spring, and the U-shaped shim if equipped.
5. Clamp driveshaft in suitable vise and install tool T.Av. 537-02 or equivalent on shaft yoke, polishing interior of tool as necessary to obtain proper fit.
6. Lubricate entirety of tool T.Av. 537-02 and the inside of replacement boot with clean motor oil.
7. Start small end of boot onto tool, gripping boot so first boot fold will stretch as boot is worked onto tool.
8. Pull boot onto tool as far as possible, then let boot relax and return halfway, ensuring first fold does not slip back. Repeat this step three or four times to stretch boot. To ease installation, wrap a dry cloth around the boot and use a two handed grip to gradually work boot onto tool.
9. Apply more lubricant to tool, then, when boot is most pliable, quickly pull boot onto large end of tool, then over the tool end and shaft yoke onto driveshaft.
10. Lubricate thrust ball and spring with suitable grease and install them in stub axle. A shim is used between the thrust ball and stub axle on some driveshafts. Do not install a shim unless the shaft was originally equipped with one.
11. Fabricate a spacer from an old shock absorber grommet and loop a length of wire through it, then install under spider and starplate.
12. Move rollers toward center and position starplate arms so that each arm is central between each spider roller, then insert shaft yoke into stub axle.
13. Tilt shaft and insert one star plate arm in yoke, then press arm into yoke slot with screwdriver.

Fig. 11 Modifying screwdriver:

14. Using screwdriver with tip modified as shown, Fig. 11, press remaining starplate arms into yoke.
15. Remove spacer from under starplate by pulling it out with attached wire, ensuring each starplate arm is securely seated in yoke slot, then check that spider moves freely in all directions.
16. Distribute grease supplied in replacement boot kit evenly between boot, rollers, yoke and stub axle.
17. Position boot in stub axle and driveshaft retaining grooves, then purge air from boot by inserting a length of smooth metal rod between boot and stub axle to exhaust trapped air, then remove rod. Do not damage boot when purging air.
18. Using tool T.Av. 1034 or J-22610, or equivalent, install small clamp on boot.
19. Install large clamp on boot, using two 1/4 inch drive deep sockets and extensions to spread clamp.