Does anyone have advice or the service manual instructions for replacing the outer CV boot on a C5? I purchased the GM boot kit (P/N 88952506), removed the axle from the car, and removed the outer joint from the axle. This allowed me to replace the old boot with the new boot. My question concerns understanding the proper procedure for reinstalling the outer joint on the axle. The kit contains a new circlip, but I do not want to merely hammer the outer joint back on the axle shaft as this would require pounding on the outer race and likely damaging the bearings/bearing surfaces in addition to the circlip. Is it necessary to disassemble the outer joint prior to reassembly? Either an explanation or a copy of the service manual instructions would be greatly appreciated.

 

http://forums.corvetteforum.com/c5-t...-and-i-survive...

Dated 12/2/2006 Nice pictured write up by chuckster

It's not coming up.
You could go to the advance search in the tech section & it will come up.

There is a certain sequence in removal & installing the 6 ball bearings, that is not mentioned in the article. Starting w/ ball (1) To remove in proper sequece. looking at the cage w/the 6 *****.
2 ***** across from one another @ top-middle-bottom.


O2 Top O4



O5 middle O1


O3 bottom O6



Sequence for install.
2O top O4


5O middle O1


3O bottom O6


What I found in regards to installing the Cir clip is to use a small radiator clamp to squeeze the clip closed. Then tap the joint till the clip is in it's propper positioin. Then take a dremmel or small chissel to remove the clamp.

You really need a parts cleaner bucket, brass punch & CV Boot clamp pliers.
I used Lisle tool #30800 Napa auto store for the clamp pliers.
Good luck.

 

Thanks for the response bumble-z. You were right, Chuckster's post had some great pics. I didn't realize that the joint just came apart. I had come to the same conclusion about compressing the circlip - I'll use a hose clamp to compress it while taping the joint back on the axle. Thanks again for the sanity check.

 

The first axle I did as the manual states in regards to install the cir clip, Big PITA!
I used the radiator clamp on the second one & made that part of the job a piece of cake.

That is a fine article & I'm glad you were able to track it down or to come up.
Another thing that is not mentioned is the location to install the band clamps. On the outer boot the large end of the boot is easy to figure out where it sets onto the cv joint to clamp.
Per manual.(Position the seal & lg retaining clamp to the outer race.
Measure the distance between the edge of the seal & the edge of the outer joint outer race last groove closing edge )
adjust to 0.8mm (0.03 in)

Position the small seal retaining clamp onto the neck of the seal. Measure the distance between the edge of the seal & the edge of the last axle shaft groove closing edge, have a gap of 2.5mm (0.10 in)

Manual also states the seal retaining clamp must not be over-tightened or under-tightened.

Good luck.

 

Good advice. Thanks again.