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By NAPA
When it comes to working in the shop, personal safety should always be the top priority. Safety glasses, gloves, hearing protection, even work boots are all meant to keep your body protected. It should come as no surprise that with new hybrid and electric drivetrains, there are also new safety gear requirements. Insulated tools are just the start of a well-stocked shop. There’s more to electrical safety than just owning a set of
link hidden, please login to view. This expert advice is meant to give an overview of the kinds of general
link hidden, please login to view (PPE) needed to service hybrid and electric vehicles. It is important to follow proper repair procedures for these vehicles, as described in the vehicle specific repair manual. This includes using all required PPE listed in the repair procedure with no exceptions. If you do not have ALL of the necessary PPE, DO NOT proceed with a repair, as doing so could lead to severe injury or even death. Now that you have an idea of the serious nature of vehicle high-voltage electrical systems, let’s take a look at how you can protect yourself. Personal Protection
Wearing the right personal protection gear is a must when working with electric and hybrid vehicle high-voltage systems. The electrical energy stored in a typical main traction battery pack is more than enough to kill or seriously injure a person.
In the past, wearing gloves while working on a car was usually a personal preference. Today, when working on high-voltage electrical systems, wearing gloves is mandatory. And not just one pair of gloves, but two pairs (inner and outer) are to be worn together. Just in case you are wondering, welding gloves are NOT the same as high-voltage
link hidden, please login to view. Class 0 gloves are required for protection up to 1,000 volts AC and 1,500 volts DC. One pair of rubber gloves (inner) protects against electric shock, while the leather gloves (outer) protect the rubber gloves from mechanical wear. They must be worn together in order to perform correctly. Electrical gloves
link hidden, please login to view every six months to ensure they are still capable of insulating the user from the rated voltage. Gloves will be labeled with the test date near the cuff. The exact personal protection gear needed for a repair will be spelled out in the vehicle service repair manual procedures. This may include an insulated apron,
link hidden, please login to view, insulated arm sleeves, link hidden, please login to view, arc flash face shield with neck protection, and insulated mats or blankets. These layers of protection are necessary not just for avoiding shocks, but also potential explosions like an arc flash. Tool Safety
It may seem odd to consider hand tools as part of personal protection equipment, but that is exactly the case when working with electricity. Most ordinary hand tools are made from metal, which does an excellent job conducting electricity. For servicing high-voltage electrical systems tools need to be designed in such a way that they don’t provide a path for electricity to travel to the technician, or to other vehicle components. That’s why EV tools are specially designed to protect the technician when used properly.
An EV tool set is a must-have for any technician looking to service an electric vehicle. A good start for insulated hand tools is an insulated screwdriver set, an
link hidden, please login to view and an link hidden, please login to view. Electric vehicle tools used for diagnostics need to handle higher voltages, like this link hidden, please login to view. For repairs where the battery pack must be removed, special care must be taken due the extreme weight involved. A link hidden, please login to view is the proper way to lower and transport a hybrid or electric vehicle battery pack. You wouldn’t pull an engine out of a car without the proper lifting equipment, so give the same respect to a heavy traction battery pack. Work Space Safety
Normally, when a car is being worked on in a service bay, there is little danger to fellow technicians. But that isn’t the case with a modern electric or hybrid vehicle. Whenever the high-voltage electrical system on one of these vehicles is exposed, proper notification must be given to those working in the area. Place
link hidden, please login to view and link hidden, please login to view around the vehicle whenever the high voltage electrical system is being serviced. This warns other technicians that there is an electrical shock hazard in the shop, and to keep their distance. You may also place an electrical warning sign on the vehicle to signal to everyone in the shop to stay away. Part of your workspace safety gear must be an
link hidden, please login to view. If a technician suffers an electrical accident while working on a vehicle, anyone attempting to help them is also in danger of electric shock. An insulated safety hook must be used to separate the victim from the electrical source. The last tip for work space safety is to never work on an electric or hybrid vehicle alone. Always let another technician or coworker know you are working on a high-voltage electrical system, and to check in on you periodically. Training Is The Key To Safety
Working on hybrid and electric vehicle high voltage systems requires meticulous procedures and extensive training. While there are plenty of dangers when working on internal combustion vehicles, many of the safety procedures surrounding those vehicles have been known for decades. As EV and hybrid drivetrain become more mainstream, so will their service safety procedures.
Tackling hybrid and electric vehicle high-voltage system repairs isn’t impossible, but there must be dedication to proper training. If you are a technician (or are wanting to become a technician), and are looking for electric vehicle service training,
link hidden, please login to view can help. NAPA Auto Tech offers a wide variety of convenient, cost-effective ways to become an automotive professional. In addition to eLearning and instructor-led training, NAPA Auto Tech offers hands-on and seminar-style classes for almost every make and model to help technicians keep their skills up to date. Photos courtesy of Brian Medford.
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By NAPA
Honestly,
link hidden, please login to view are rarely a topic of discussion around automotive maintenance until something goes wrong. A torn CV boot seems like a minor issue at first, but if the situation is not remedied quickly, more damage will occur. A CV boot keeps lubricating grease from escaping the spinning link hidden, please login to view. Without grease, the CV joint will wear out rapidly. CV boots also protect the CV joint from water, dirt and road debris. For an often-forgotten replacement part, the CV boot performs a pretty critical job. For even more technical insight, check out “ link hidden, please login to view” CV boots aren’t just for front-wheel-drive vehicles either. Any vehicle design that must transmit power to a wheel, while also allowing for suspension movement, might utilize a CV joint. For example, a late-model, rear-wheel-drive
link hidden, please login to view has an independent rear suspension and two CV axles, each with two CV boots. A late-model, front-wheel-drive link hidden, please login to view also has two CV axles and four CV boots. But, in comparison, an all-wheel-drive link hidden, please login to view has four CV axles and a total of eight CV boots. Is It Possible Fix a CV Boot?
If you’re searching for a how-to guide on replacing a damaged CV boot, you came to the right place. Let’s walk through a CV boot replacement with the help of some NAPA expertise. Keep in mind, a CV axle boot replacement is only for
link hidden, please login to view that are still in good shape. If your CV axle is clicking or the CV boot was damaged and leaking grease for an extended length of time, you need to replace the entire CV axle. Installing a new CV boot and applying
link hidden, please login to view won’t fix an already damaged CV joint. Also, the labor to just replace a CV boot is nearly the same or greater than replacing the entire CV axle assembly. If the link hidden, please login to view costs as much as a new or rebuilt CV axle, the smart choice is to replace the entire CV axle. How Long Does It Take to Replace a CV Boot?
The time it takes for CV axle boot replacement varies by vehicle. Most of the labor time involves removing the CV axle from the vehicle. Budget at least an hour for the job if the CV axle is easy to remove or up to three hours if the vehicle is complicated. Cleaning the CV joint can take another 30 minutes as well.
How to Replace a CV Boot
A typical
link hidden, please login to view includes a new CV boot, two CV boot clamps and grease. Replacing a CV boot requires lifting the vehicle off the ground for easier access to the underside. A repair shop or well-outfitted home mechanic will utilize a vehicle lift, while a DIYer can use something as simple as sturdy link hidden, please login to view. Never use a floor jack to support a vehicle, as they can suddenly fail. Lift the vehicle off the ground. Use a wheel chock to prevent any wheels on the ground from rolling. Remove the wheel on the axle that needs repaired. Refer to a repair manual for what steps to follow to access the CV axle. You will likely need to remove the brakes and detach steering and/or suspension components, as well as the axle nut. Remove the CV axle from the vehicle and place it on a workbench with plenty of working space. Cut off the failed rubber CV boot. The metal CV boot clamps will likely require a pair of link hidden, please login to view. Due to the potential mess caused by the CV joint grease, we recommend wearing a pair of disposable work gloves for this step. Refer to your repair manual for how to remove the CV joint from the axle shaft. Note that inner and outer CV joints are possibly different and might require distinct methods of disassembly. Clean the axle shaft to remove any old grease. Use a link hidden, please login to view to clean the CV joint. Let the CV joint dry thoroughly. If using non-split CV boot clamps, slide them over the axle shaft now. Slide the new CV boot onto the axle shaft, taking care to orient it correctly. The large cone opening should face the CV joint. You may need to use a small amount of silicone lubricant to help move the boot along the axle shaft. Refer to your repair manual to link hidden, please login to view using the correct specified grease. Refer to your repair manual to reinstall the CV joint onto the end of the axle shaft. Slide the CV boot over the CV joint, making sure it is seated evenly. Using the link hidden, please login to view, tighten both CV boot clamps. Reinstall the CV axle along with any components that were removed to access the CV axle. Pay attention to torque specifications during reassembly. Reinstall the wheel and tighten the lug nuts to the correct specifications. Lower the vehicle back to the ground. How Much Does It Cost to Replace a CV Boot?
CV boot replacement cost can range from $300 to $900 depending on the vehicle. It is wise to price out replacement of the entire CV axle as well. In some cases, it is smarter to spend a little more money to replace the entire CV axle rather than spend time changing just a CV boot. Check out the
link hidden, please login to view for a better estimate of what this repair would cost for your vehicle (if applicable). Now that you know the typical steps of how to replace a CV boot, you can decide if this repair is something you can tackle yourself. Your local NAPA Auto Parts store can help you find the right CV axle boot repair kit for your application. You can also shop NAPAonline for
link hidden, please login to view on more than 160,000 items! Don’t feel like doing it yourself or don’t have the time? The link hidden, please login to view at your local link hidden, please login to view have you covered with more than 17,000 locations nationwide. Photo courtesy of
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