How to replace an ATV cv joint?

Answer 1

1. Jack your vehicle off the ground and secure it from rolling
2. Remove the wheel
3. Remove the axle nut (large nut on the outside of the hub)
4. Remove the lower control arm bolt from the hub assembly
5. The hub will be able to swing out away allowing the axle to be slipped out through the back. This may require a tap on the threaded end of the outer cv joint. Put the axle nut back on half way so that you can tap on it without damaging the threads.
6. The inner u-joint will be the only thing holding it axle in place. That can be removed by knocking out the roll pin which holds it to the front differential. Now you should be able to pull it off the stub shaft.
7. Once the axle is out of the vehicle. Hold the cv axle by the shaft close to the inner u-joint and hit the outer cv joint off of the shaft with a hammer (I use a 5 lb sledge. (wear glasses, grease may fly!) It usually comes off with one or two good blows with the hammer. However, If it doesn't come off put the axle in a vise and try again. If it still doesn't come off use your hammer to break the cage and remove the ball bearings. This will expose the race. You'll need to press the race off of the shaft. You can use a punch and hammer to punch the shaft back through the race. Other wise you'll need to use a press. Or cut it off with a cutoff saw. Cut the race in the direction of the splines on the shaft. That way it won't affect your new joint going onto the splines.
8. Now that the joint is removed cut away the old boot and clamps and clean the shaft with parts cleaner or Brake clean.
9. Put on the new boot and slide it toward the inner out of the way.
10. Cut the corner of the grease packet to make it like a baker's bag. This will allow you to squirt the grease into the hole were the shaft will go. Fill the outer cv joint until the grease comes up around the balls and set the rest aside for later in this procedure.
11. Now put a little grease on the "c" clip on the shaft to help hold it centered
12. Take the outer cv joint and line up with the splines of the shaft and make sure that your clip is not sticking out to one side or the other.
13. Now place the axle nut onto the threads half way to avoid damaging the threads and tap the joint back onto the shaft. If it doesn't go fairly easily then back off and use a screw driver the tap the clip in while putting pressure until it is no longer exposed then the joint will tap on with ease.
14. Now squirt the remaining grease around the top of the joint (it may not require all of the grease packet just use about a 1" bead all the way around) were the shaft meets the joint and slide your boot down and clamp the large clamp first.
15. Now use a screw driver to go in between the small end of the boot and shaft to release any trapped air or suction that may be deforming the boot. Then install the small clamp.

Now ready to install the axle. Just use your removal procedure in reverse.