Ack's FAQ: Your 4X4 Portal To All Things Suzuki/Geo

Rebuilding Sidekick/Tracker/Vitara CV Halfshafts

Here is a cutaway picture of the inside CV joint on the bolt-on halfshaft. The splined halfshaft CV joint dissassembles the same way.

• 1. Remove the boot bands (item 4 and 7).

• 2. Slide the boot back down the shaft.

• 3. Feel inside the edge of the cup for the spring retaining ring.

• 4. Use a very small screwdriver to pry under the spring and pop it out.

• 5. Slide the joint out of the socket.

• 6. Observe and remove the circlip ring that holds the ball joint assembly onto the shaft. Get a GOOD circlip removal tool for this. you'll use this tool a lot elsewhere so go ahead and spend some money.

• 7. Slide the ball joint assembly off the shaft.

• 8. Slide the boot off the shaft.

• 9. Remove the retaining bands on the boot at the other end and remove that boot.

• 10 Install new boots and grease as pictured in the above drawing following the instructions in reverse order.

• 11 Reassemble in reverse order.

The boot rebuild kit (one side - two boots) is less than $15.00 US (2005) at most auto parts stores.

The metal retaining bands that hold the boots in place are a "beeache" to put on and require a special tool. Look into renting or borrowing this tool as I found that Wire Ties (sometimes called "Baker Ties") just won't do the job no matter how tightly you cinch them up.

UPDATE
The following video gives a general description of how to disassemble the outer CV joint: