1991 911 C2 964 CV Boot replacement

[barry longmire]

I have two torn CV boots (one inner and one outer) on my 91 911. I'm wondering how difficult it is to replace the boots and it the axle must be completely removed. I would appreciate any comments.

[RetiredRider]

You will need to remove the axle. Hardest part is getting a torque wrench that will scale to 350 ft-lb when torquing the axle nuts. I would also suggest replacing the rear axle bearings as well.

Search this forum for CV boot replacement and CV joint rebuild. There are several detailed articles describing a good step by step procedure.

[LouZ]

You don't have to completely remove the axle! you can unbolt the flange at the diff, then take out the "C" clip and remove the inner CV. Remove both boots, then just slide the outer boot on and install it on the outer CV, and just follow up with the inner boot and reinstall the CV joint and button things up.


It took me about an hour per side laying on the floor with the car on jack stands (now I have a lift!)

[barry longmire]

Originally Posted by LouZ

You don't have to completely remove the axle! you can unbolt the flange at the diff, then take out the "C" clip and remove the inner CV. Remove both boots, then just slide the outer boot on and install it on the outer CV, and just follow up with the inner boot and reinstall the CV joint and button things up.


It took me about an hour per side laying on the floor with the car on jack stands (now I have a lift!)

Lou - That is what I was hoping! Is the flange removed using an Allen wrench? Where is the "C" clip (next to the diff or on the shaft)? Should the bolts be replaced or can I reuse them?
Thanks for your help!
Barry

[Vandit]

You're going to want to use a quality Allen bit (3/8" or 1/2" drive). You'll probably end up stripping the bolts if you try to go in there using a simple Allen wrench.

I replaced the bolts. They're not that expensive.

I was aware that it could be done w/o removing the axles from the hub, however, since*I bought my car w/ a couple of torn boots, I didn't know how long they had been busted (possibly contained contaminated grease). I removed the axles so I was able to really degrease the joints and add fresh grease.

The axle nut at the hub did require me to use a 18" breaker bar and a 2' cheater bar to get them loose and retighten them. No actual torque measurement taken since my wrench only reaches 250ft/lbs. I marked the nut w/ paint and it hasn't moved in the past 4k or so miles.

[bazar01]

Originally Posted by Vandit

You're going to want to use a quality Allen bit (3/8" or 1/2" drive). You'll probably end up stripping the bolts if you try to go in there using a simple Allen wrench.

I replaced the bolts. They're not that expensive.

I was aware that it could be done w/o removing the axles from the hub, however, since*I bought my car w/ a couple of torn boots, I didn't know how long they had been busted (possibly contained contaminated grease). I removed the axles so I was able to really degrease the joints and add fresh grease.

The axle nut at the hub did require me to use a 18" breaker bar and a 2' cheater bar to get them loose and retighten them. No actual torque measurement taken since my wrench only reaches 250ft/lbs. I marked the nut w/ paint and it hasn't moved in the past 4k or so miles.

I agree.

If the boots have been torn for a while, it has been exposed to the elements and the only proper way to do it is to take the axles out, clean the CVs, regrease and put on the new boots. Might as well change the rear bearings as well since the axles are out.

[LouZ]

Originally Posted by barry longmire

Lou - That is what I was hoping! Is the flange removed using an Allen wrench? Where is the "C" clip (next to the diff or on the shaft)? Should the bolts be replaced or can I reuse them?
Thanks for your help!
Barry

To remove the Allen bolts, try my trick:

Put a screwdriver in one of the slots in the rotor. Use a slot that's visible thru the brake caliber. Turn the rotor so the screwdriver catches on the inside edge of the caliper, then just break the bolts loose. To tighten, just move the screwdriver to the other side of the caliper.

The "C" clip is on the CV, you will need to pop the gold colored cap off the end then fish thru a big glob of grease. You will need the "pin" pliers to get the clip off and on.

I've replaced the bolts once, but since then had the axle off and on and reused the same bolts. They are not expensive and will offer you a good night's sleep!