Bailcast CV 96 Universal CV Boot Kit (Standard)

The cut to size deisgn on the CV96 enables it to fit most cars which in turn reduces the amount of CV boots that are needed to be stocked. As well as this the design of the boot allows for superior flexibility which minimalises wear and tear especially when the vehicle is on full lock.

The CV96 Universal CV Boot is resistant to:

Oil & grease,
Abrasion,
Grit,
Extremes of temperature,
Tear and impact damage.

CV96 fits most cars as well as some 4×4’s and light commercial vehicles.
Fits joints measuring:
Shaft: ø18-26mm
Joint: ø56-116mm
Length: 58-128mm

Can be fitted to trilobal/tripod joints, follow the simple step by step instructions found printed in the box or below.

Can be fitted using the conventional cone method.
Alternatively the boot can be stretched using either of our innovative tools, Duragun® or Duralec®, which will enable the job to be fully completed in only 20 minutes, a fraction of the conventional time.

Covered by our 2 year ‘No Quibble’ quality guarantee.

Available from all good Distributors and Motor Factors

Kit Contains:
CV Boot, Grease Sachet, Small and Large Ear Clamps

INSTALLATION

Ensure vehicle is correctly supported with road wheels secured, in line with manufacturers guidelines.
 Remove road wheel
 To find correct cutting point check sizing guide below against the old boot.
Shaft Ø 18-26 18-26 18-26 18-26
Joint Ø 56-75 J1 73-98 J2 83-111 J3 87-106 J4
Length 58-71 72-89 87-107 104-128
 Remove old boot and clips.
 Clean away any grease or debris from shaft and joint.
Installation Tip: Do not use WD-40 or similar product to clean CV joint, it will leave a residue when dry that will
negatively affect the new CV grease.
 Check fitting cone FC1 for sharp edges or rough areas. Smooth with emery cloth if required, spray entire outer surface with CSP50 cone spray.
 If fitting new boot to outer CV joint turn boot inside out.
Installation Tip: Warming the boot will help make it more flexible, this is recommended if installing in low temperatures or if boot feels stiff.
 Spray cone and contacting side of boot with CSP50 cone spray.
 Place large end of boot over narrow end of cone FC1 and then place cone FC1 over joint.
 Push boot, forcefully, until it is on joint clear of cone. Remove cone and turn boot right side out, if necessary.
 Tear open grease sachet spout, at tear point, and fill joint.
Installation Tip: Fill joint only, do not fill CV boot with grease. Dispose of remaining grease in line with local authority regulations.
This can have a detrimental effect on the CV boot. If remaining grease is packed in to CV boot the mass coupled with centrifugal force will cause the
boot to distort. This can lead to the boot coming away from the joint or premature wearing due to contact with surrounding surfaces.
 Slide and stretch boot into position over the joint.
Installation Tip: If boot slides off joint during installation it is usually because CV grease is on inside of boot and outside of joint. Wipe grease off both.
Trapped air will also cause the boot to slip off. Release air and the boot will suction onto joint.
 Secure the boot with fixing clips provided using ECP1 ear clamp pliers.
Installation Tip: A properly tensioned clamp will be tight enough so CV boot will not turn on joint, but not so tight that it will pinch and damage boot.
Only use ECP1 Ear Clamp Pliers to fit clamps, other pliers can cut/stress the clamp leading to failure.
 Replace hub and road wheel.

TRILOBAL JOINT

 Clean outside of the old boot at the joint side, using a suitable cleaner.
 Trim the old boot 10-15mm from the joint leaving the trilobal part of the boot in position.
This creates an exact fit adaptor that the new CV Boot can be attached to.
 Remove the old clamps and boot leaving only the trilobal part in place on the joint.
 Clean away any grease and debris from the shaft and joint.
Installation Tip: Do not use WD-40 or similar product to clean a CV joint, it will leave a residue when it
dries that can negatively affect the new CV grease.
 Wipe the outside of the remaining trilobal part of the boot (all grease and debris should be removed to
obtain a good seal).
 Fit the new CV boot as detailed above, clamping the large end over the adaptor that has just been created.