Last year I saw that my CV boot was torn and had sprayed grease everywhere. I've probably driven it 500-1000 miles since then. And a couple jeep trails. But it hasn't gotten wet.

Do I need to replace the entire half shaft assembly, or can I just replace the boot and refill it with grease?

This truck has stock suspension with the torsion bars cranked all the way up to fit big tires. So the CV joints are always at a pretty steep angle.

 

I'd replace the shaft. The joint may have dirt in it and may not last that long anyway. But if you are doing the work yourself you won't be out that much to try just the boot first.

 

If you think it hasn't gotten wet or too dirty, you can remove the boot, flush it out good with grease, then reboot it.

If it starts making popping noises then replace it. Who knows, it might be OK. If not, worst case, you wasted some time, grease and a boot.

I've gotten lucky doing this with many vehicles. I'd say 65% of the time. Which is good enough for me.

 

You have to take the shaft apart to replace the boot. They make a wrap-around boot, but they are not particularly reliable, especially with the flex you are putting on it by lifting the truck as far as the torsion bars will take it.

Pull the shaft out, it's not very hard. I cannot tell you how to do it, but I could easily figure out how to do it if I had to. While it's out, you can take the CV joints apart and clean them with a solvent, then repack them with fresh grease.

A CLUE IF IT HAS TO BE REPLACED
Go to a parking lot and go in a circle with the steering wheel turned to full lock, then go in another circle going the other way. If there is a clicking noise, then the axle should be replaced. You could clean it and roll the dice, but if there is noise from it then it is generally beyond help that you can give it at home.

Be mindful that the side with the torn boot might not be the side that needs to be replaced because of the clicking noises you hear while going in a circle.

 

Being that you have to take the shaft apart to replace the boot, you might as well just replace the whole shaft. They aren't that expensive.

 

Thanks for the suggestions. I don't think I hear popping from the axles, at least over all the engine noise and the groaning of the steering pump.

A new Motorcraft shaft is around $300, which makes me want to try replacing the boot first... But, there is a Cardone rebuilt shaft assembly for $80, which would make it a lot easier to just replace the assembly. Does anyone have experience with the rebuilt shaft assemblies -- are they as good as new?

 

No they aren't, but just find one with a good warranty.

 

Okay, I missed the part about the results of turning the steering wheel to full lock and going in a circle, then turning to full lock the other way and going in a circle again.

If clicking noises, then taking the CV joints apart and cleaning them, and putting them back together with a fresh load of grease may not give any joy -- replacing the shaft will be needed. But if there are no clicks AND you have a torn boot, then you can clean the joint, pack with fresh grease, and install a new boot, and drive happy. The dollars needed to fix this, and the success you will enjoy depend on the results of the simple test I suggested.