Kia 495942F201 Boot Set-Out Joint

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Complete rebuilt driveaxles are available on an exchange basis, which reduces time and effort. Some auto parts stores offer "split" type replacement boots that can be installed without removing the driveaxle from the vehicle. However, it's advisable to remove the driveaxle, disassemble, and clean the CV Joint to ensure it is free from contaminants like moisture and dirt. Once the driveaxle is removed, it should be mounted in a vise with the jaws lined with wood or rags to prevent damage.For INNER CV JOINT - TRI-POT TYPE: If you're uncertain about the outer boot's condition, now would be an ideal time to replace it. Cut off both boot clamps, slide the boot towards the driveaxle's center, and discard the old clamps. Scribe or paint alignment marks on the outer race and the tri-pot bearing assembly. Then slide the outer race off the tri-pot bearing assembly and remove the snap-ring from the axleshaft end. Secure the bearing rollers with tape, remove the tri-pot bearing assembly from the axleshaft using a brass drift and hammer, then remove the tape, ensuring the rollers don't fall off. Discard the old boot.For inspection, clean the grease from the outer race and tri-pot bearing assembly. Disassemble each tri-pot assembly section one at a time to clean the needle bearings with solvent. Check the rollers, tri-pot bearings, and outer race for signs of wear.During reassembly, wrap the axleshaft splines with tape, slide the new boot on, then remove the tape. Place the inner stop-ring, slide the tri-pot assembly onto the axleshaft, and install the outer snap-ring. Use CV joint grease on the inner bearing surfaces to keep the needle bearings in place when reassembling the tri-pot assembly. Ensure each roller is reinstalled on its original post. Pack the outer race with half the provided grease, place the remainder in the boot, and install the outer race. Equalize the pressure in the boot using a blunt screwdriver and install new boot clamps.For INNER CV JOINT - BALL-AND-CAGE TYPE: Remove clamps from the boot, slide it back on the axleshaft, and pry the wire ring ball retainer from the outer race. Pull the outer race off the inner bearing assembly and wipe off excess grease. Remove the snap-ring from the axleshaft end, slide the inner bearing assembly off, and note that further disassembly isn't recommended.For inspection, clean components with solvent and inspect the cage and races for wear. If there's damage to the outer CV Boot, now's the time to deal with the inner CV joint.For reassembly, wrap the axleshaft splines with tape, slide the new boot on, and remove the tape. Install the inner race and cage assembly, snap-ring, and fill the boot with CV joint grease. Pack the inner race and cage assembly with grease, install the outer race, and wire ring retainer. Wipe off excess grease, seat the boot in the appropriate areas, and install clamps.For OUTER CV JOINT AND CV Boot: Remove the inner CV joint from the driveaxle. If the driveaxle has a dynamic damper, mark its location on the axleshaft, cut the retaining clamp, and slide the damper off. If replacing the axleshaft and outer CV joint assembly, measure the distance between the Inner CV Boot and dynamic damper. Cut the boot clamps from the outer CV joint and slide the boot off.For inspection, wash the inner and outer CV joints in solvent and dry them.For reassembly, slide the new outer boot onto the axleshaft, add the specified amount of grease to the outer joint and boot, and install new clamps. If equipped, align the dynamic damper with the mark. Clean and reassemble the inner CV joint, then install the driveaxle.