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Old 07-08-2019, 07:03 PM
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need help ASAP with 35 spline rcv assembly!

every video i saw showed them sliding the shaft right through the boot of the rcv, so i assembled the joint thinking i could do the same, not realizing that the 35 spline end is much to big to fit through the boot, and now i can't get the joint apart to slip the boot on and re assemble the joint! what can i do!? can i boil some water to try to get the boot soft enough to slip over the end?

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Old 07-08-2019, 07:12 PM
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the boiling water didnt work, still not flexible enough to slide over..............

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2011 JKU Sport: 40x13.50r17 Nitto Trail Grapplers, vision nemesis wheels, 4.75" EVO coils, 1" body lift, Falcon 3.3 shocks, Fusion 4x4 hybrid dana 60 axles
Overkill gets you off the trails and keeps you and those with ya enjoying the day
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Old 07-08-2019, 08:34 PM
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going to be the first time i have to pay someone else to do something on my jeep because i can not do it. if i break the rcv joint, then my trip to rausch is out the window, so im going to try to have a shop take them apart tomorrow.



much drinking is being done right now!!! (im going to be the one on the right here tonight!)
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2011 JKU Sport: 40x13.50r17 Nitto Trail Grapplers, vision nemesis wheels, 4.75" EVO coils, 1" body lift, Falcon 3.3 shocks, Fusion 4x4 hybrid dana 60 axles
Overkill gets you off the trails and keeps you and those with ya enjoying the day
For those that get it, no explanation is needed. For those that don't, no explanation is possible.
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Old 07-09-2019, 10:21 AM   #4
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The boot should slide on the long end without too much effort, I know mine did. It's getting the boot over the CV joint that is the problem.

To remove the boot from the joint you need to break the vacuum that the boot creates on the joint. I recommend a couple of tie wraps when installing the boot and a couple of straight screwdrivers to remove the boot. If you have to break the CV joint apart, you got to whack it, usually in a vice, to seperate them.

I had to take mine apart a couple of times when I installed them, I put the axle in a vice and used a dead blow hammer to separate the joint. Yup, scared the crap out of me the first time I did it.
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Old 07-09-2019, 11:39 AM
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the problem i was having, is the 35 spline on the diff side is 1.5" diameter and the outer at the hub, which is also the sealing size of the boot on the shaft is about 1-1/4 to 1-3/8", so the boot would have to stretch a good bit to get on the shaft.


what i ended up doing is using a heat gun to soften the boot up and gave it a whack with a rubber mallet and it slid right on the shaft! everything is going good now, the axles are in and im just doing the final re-assembly of my front end now, then i can start the gear break in process.
Laggy and Cummins_Powered like this.
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Overkill gets you off the trails and keeps you and those with ya enjoying the day
For those that get it, no explanation is needed. For those that don't, no explanation is possible.
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