Q: How to replace the outer CV Boot and CV Joint on Chevrolet Malibu?
A: To replace the wheel drive shaft outer joint and boot, start by to using a side cutter to remove the large seal retaining clamp from the CV Joint and toss it away, taking care not to cut through the inboard or outboard boot and risk damaging the sealing surface. If there is a swage ring to a small size, cut through if without wrecking the halfshaft bar, with a hand grinder. Else cut the small seal retaining clamp out with a side cutter and throw it away. Remove the halfshaft outboard seal from the CV Joint outer race from the big diameter and slide the seal from the joint across the halfshaft bar. Remove grease from the face of the CV Joint inner race and properly spread the ears (on the race retaining ring) using j 8059 to remove the CV Joint assembly from the halfshaft bar. Detach and dispose of the old outboard seal, after which take a brass drift to lightly tap and tilt the CV Joint cage in order to eliminate the first chrome alloy ball and continue that process six times for all the balls respectively. Pivot the CV Joint cage and inner race 90 degrees toward the centerline of the outer race, align the cage windows with the lands of the outer race, and lift the cage and inner race. Lift off the inner race from the cage and clean the inner and outer race systems, CV Joint cage, and chrome alloy balls carefully with cleaning solvent until you have removed the old grease and contaminants and dry them thoroughly. Inspect the CV Joint assembly for abnormal wear, cracks, or defects, replace the defective parts and clean with the use of a wire brush in the seal mounting area for rust. For installation, insert the halfshaft in a vise, install a new small eared clamp on the neck of the outboard seal without crimping, slide the outboard seal on to the halfshaft bar and fit it in the seal groove. Take a crimper for the eared clamp and use it with a breaker bar, j 35910, and a torque wrench while hanging up to 136 nm (100 lb ft), measuring the gap dimension and crimping as required. Use a light coat of grease from the service kit in the grooves on the ball of the inner and outer races spin the inner race 90 to the center line of the cage and insert it into the cage. Even up the cage and inner race with the outer race and make sure the retaining ring side of the inner race is put towards the halfshaft bar; then have them inside of the outer race. Put the first chrome ball, tip the cage to get the second one and continue by doing this until all 6 have all balls in place. Pack the CV Joint with grease from the service kit and push CV Joint unto the halfshaft until the retaining ring is seated; ensure that the outboard seal is not dimpled or stretched and reshape as necessary. Pry out the bearing assembly locking pin, and slide the heavy diameter of the outboard seal with the heavy seal retaining clamp over the CV Joint outer race, find that the seal lip falls into the groove, crimp the seal retaining clamp with j 35910 to 174 nm (130 lb ft). At the same time, check the gap dimension of the clamp ear, tighten until the gap dimension of 1.9 mm (5/64 in) is achieved.