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Cv boot failure - 2003 Subaru Baja

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The best thing to do is completely remove the front drive shaft (assuming you are talking about the front CV boots).
1) Jack up the front end of the vehicle.2) Remove front wheel(s), track rod ends and slacken [don't remove completely just yet] the centre hub nut and remove split pin.3) With the gear in neutral, and using an appropriately sized round punch and hammer, punch out the location pin from the drive shaft where the drive shaft meets the gearbox output shafts.4) With the assistance of a flat screwdriver, lever and pull the drive shafts off the gearbox output shafts and let them drop down. 5) Using a rubber mallet, hammer the drive shaft through the front hub. You kept the nut on the end of the shaft initially so as to prevent damage to the drive shaft threads during hammering. This nut will have to be backed off and eventually removed as the shaft slides through and out of the hub unit.
With the entire shaft removed from the vehicle:
1) Cut off or slacken and remove any rubber boot retaining clips.2) slide the rubber boot(s) towards the centre of the shaft.3) Remove the inner joint first by using a small, flat screwdriver to flick out the retaining wire from the inner lip of the joint. (Keep this wire)4) Slide off inner joint cup and clean.
5) Locate the spring clip from the inner end of the shaft and carefully remove without over-stretching. if you have no replacement.
6) Slide off inner C.V. joint, and clean.
7) Remove damaged boot(s), clean all components, re-grease with LM grease and replace.
8) Reinstallation is the opposite of removal steps.


Note: Take care when re-installing drive shaft to gearbox output shaft. This will usually only align to a single position. Before tapping retaining pin back into place, visually inspect alignment of the shaft's holes. You can use your round punch to help align the holes before re-installation of the retaining pin.


Tip: With the removal of the front drive shafts, it may be a good opportunity to also replace front gearbox output oil seals and front wheel bearing-drive shaft dust seals. These are fairly inexpensive and may prolong the life of components as well as reduce the need for repetitive removal of parts.

Posted on Nov 04, 2012

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