Volvo CV Boot Kit - GKN 31256233

Installed these outer boots when the outer CV boot on the passenger side axle ripped and was leaking grease, I bought two of these as well as two corresponding GKN inner boots (GKN #31256223) for a non-turbo, manual transmission S60. Caught it early thankfully so no damage to the CV joint from lack of lubrication. To anyone considering the job, I unbolted the caliper and pulled the strut mounts off the knuckle and removed the axle from the gearbox, leaving the ball joints in place. The axle had been in the bearing for some time so I used an air hammer to break the axle loose from the bearing, using an old socket as a guard from damaging the axle (hit on that in between the axle and the hammer). After that I pulled the axle assembly from the gearbox and onto the workbench. From there, I needed to remove the CV joint itself from the axle which was a bit of work, though a 2lb bronze hammer and vice made the job possible to allow force to be applied without concern for damaging anything. There is a circlip holding the outer CV onto the axle shaft so the R&R process was the biggest challenge. I cleaned both the inner and outer CV joints thoroughly to remove the old grease. A bucket and a few cans of non-chlorinated brake clean worked well. I then took one of the included CV axle grease packs that came with the kit to work it into the bearings thoroughly, articulating the bearing to ensure it was thoroughly packed. As I slipped the boot over the axle I packed the contents of the second grease pack into it before sliding the included Oetiker clamps into position. The Oetiker ear clamps were a perfect fit, though I recommend getting a dedicated tool for tightening these down. I got the Lisle CV Boot Clamp Pliers sold by FCP, but even with the tool it was a bit of a careful process to ensure I got them evenly tightened. Perhaps a set of pliers could do similar, but I am glad I had the dedicated tool and they were not expensive. If you damage one of these during install they are a pain to find individually as I cannot see FCP sells just these size clips. The clamp tool simultaneously depresses the middle of the ear on the clamp I believe to help center the tool as you tighten and provides the clamp some added rigidity. After seeing how they work to lock the boot down like a vise I would not rely on any other clamp to substitute. Another note is these outer boots are made of TPE (thermoplastic elastomer) instead of rubber like the inner GKN boots I received, so they will not stretch if you have a tool like a pneumatic CV installation tool or the simple plastic stretching CV installation tool, either where you turn the boot inside out and stretch it over the CV joint. TPE is much more rigid and will not stretch like rubber. The kit includes a new circlip for the axle to hold the CV joint in place which I used. The included axle bolt is important to have, they are one time use. I tightened mine as instructed to ~26 ft/lb and then an additional 90 degrees after this and left witness marks for when I go back to check them later. Overall, the GKN boots fit perfectly and the axle looks new again.