HOW-TO: Replace CVs & Axles

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August 23, 2016
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CV axles are used to drive every model UTV and independently suspended ATV on the market. Whether replacing a torn CV boot, a broken axle, or even upgrading to stronger or longer axles for an aftermarket suspension, as an ATV enthusiast, you are bound to be tearing into one at one time or another. While it looks a bit scary, there really is little mystery to axle repair, and the same basic process can be used on almost any model CV axle.

We will show you how to rebuild a broken RZR XP axle with OEM Polaris parts, but you can use these same steps for CV boot replacement with a boot kit from Moose Racing or All Balls. MTA also has a new, reasonably priced line of Slasher CV axles and boots.

Tools needed:
• Bench vise
• Dead blow or brass hammer
• Needle-nose pliers
• Side dikes
• Small flat screwdriver
• Band clamp tension tool
• Moly CV-joint grease

STEP ONE Remove the axle from the machine. Secure the vehicle on jack stand using a wheel underneath the skid plate as a safety. Remove the link or A-arm retaining bolt and hub-retaining nut from the end of the axle, and remove the hub assembly from the axle.
STEP ONE
Remove the axle from the machine. Secure the vehicle on
jack stand using a wheel underneath the skid plate as a safety.
Remove the link or A-arm retaining bolt and hub-retaining
nut from the end of the axle, and remove the hub assembly
from the axle.
STEP TWO Use a swift pull straight out on the shaft to remove the axle assembly from the differential. A couple of quick pops should be all it takes to get them out.
STEP TWO
Use a swift pull straight out on the shaft to remove the axle
assembly from the differential. A couple of quick pops should
be all it takes to get them out.
STEP THREE You will need a clean work area with plenty of rags, as this is a messy job. Use a degreaser and clean the axle assembly before disassembling it to prevent contaminants from getting into the CVs. Use a small screwdriver or side dikes to open the CV boot clamps.
STEP THREE
You will need a clean work area with plenty of rags, as this
is a messy job. Use a degreaser and clean the axle assembly
before disassembling it to prevent contaminants from getting
into the
CVs. Use a small screwdriver or side dikes to open
the CV boot clamps.
STEP FOUR Pull the boots away from the CV joint and up the axle. Clamp the axle in a vise; clamp where the boot covers if the axles are painted or powdercoated. Grasp the joint as shown and smack the CV joint with the dead blow or brass hammer. It will take a bit of force to drive the joint off the axle. Flip the axle around in the vise and repeat the same process for the other side.
STEP FOUR
Pull the boots away from the CV joint and up the axle.
Clamp the axle in a vise; clamp where the boot covers if the
axles are painted or powdercoated. Grasp the joint as shown
and smack the CV joint with the dead blow or brass hammer.
It will take a bit of force to drive the joint off the axle. Flip the
axle around in the vise and repeat the same process for the
other side.
STEP FIVE Keeping everything laid out in order, clean the parts and replace the parts that are damaged. Slide the boots onto the axle, and then install the small clip onto the axle end. Be sure to use the proper boots on the correct ends of the axle.
STEP FIVE
Keeping everything laid out in order, clean the parts and
replace the parts that are damaged. Slide the boots onto the
axle, and then install the small clip onto the axle end. Be sure
to use the proper boots on the correct ends of the axle.
STEP SIX You can either hold the axle in the vise and drive the joint onto it, or, if you have a table with a hole in it, you can place the joint securely in it and drive the axle down into the joint. If you have any issues keeping the clip in place, you can make a temporary ring compressor with a zip-tie, and then cut it off after assembly. Flip the axle over and repeat for the other side.
STEP SIX
You can either hold the axle in the vise and drive the joint onto it, or, if you have a table with a hole in it, you can place the joint securely in it and drive the axle down into the joint. If you have any issues keeping the clip in place, you can make a temporary ring compressor with a zip-tie, and then cut it off after assembly. Flip the axle over and repeat for the other side.
STEP SEVEN Pack the CV joints with a high-quality, Moly, CV-joint grease, and then clean the clamping surface free of grease. Slide the boots into position and install the new CV boot clamps.
STEP SEVEN
Pack the CV joints with a high-quality, Moly, CV-joint grease,
and then clean the clamping surface free of grease. Slide the
boots into position and install the new CV boot clamps.
STEP EIGHT There are two different types of CV boot straps. To tighten and secure the CV boot clamps, you will either need a set of side dikes or an actual CV boot-strap tightening tool. This tool can be rented or purchased at any automotive parts store.
STEP EIGHT
There are two different types of CV boot straps. To tighten
and secure the CV boot clamps, you will either need a set
of side dikes or an actual CV boot-strap tightening tool. This
tool can be rented or purchased at any automotive parts
store.
STEP NINE Replace your rebuilt CV axle into your UTV or ATV. Be sure to use LocTite, and place any spring washers or circlips in the same position. Re-torque your wheels and enjoy your ride.
STEP NINE
Replace your rebuilt CV axle into your UTV or ATV. Be
sure to use LocTite, and place any spring washers or circlips
in the same position. Re-torque your wheels and enjoy your
ride.

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