Phoenix,
Never tried a stretchy boot but I've heard that they are pretty good. You just need a degree of faith that they will stretch far enough. Split boots - only in an emergency - it does exactly what it says on the tin - splits.
Any time I've done a CV joint it's been a real pig getting the circlip out. I've tried all sorts of maneouvers but generally resort to destroying the old circlip getting it out.
Biggest problem I've found is the fact that the stub axle through the wheel bearing is REALLY tight. It has been flooded with adhesive on assembly. You need to disconnect the bottom ball joint so that you can release the inner spider joint, then re-attach the ball joint again so that you have something to purchase against. Now get a really BIG hammer and a good solid drift to knock it out. Even once it starts to move you might find that it needs hammering all the way out.
Now clean out all the remaining adhesive from the splines, on the stub axle and in the hub. I used a small needle file and just picked away at it. You might need to dress the end of the threads where you hit it to get past the first damaged thread.
Cut off the remains of the old boot, clean out as much of the old grease as you can but don't wash out with parafin, petrol of the like. Not unless you feel up to stripping the balls out and dismantling the whole joint. Boy is it fun puting it back together again !
Pack with new grease from the CV joint boot kit and slip the new boot over the inner shaft. Fit a new circlip and reinsert the shaft into the joint. You should feel a positive 'click' as the circlip snaps into the land on the shaft. Boot back in place with new cable ties. ( I've never had much luck with the fancy metal clips they supply.)
Now, with some luck, the splines slide back into the hub without too much persuasion. You'll not get the centre nut tightened until everything else is reassembled and the wheel is back on the ground. I seem to remember that it requires about 300 Nm torque but best to check. I managed to borrow a suitable torque wrench to do the job. But I guess 14 stones on the end of a 2 foot bar won't be too far off.
Paul @ Kippen.
