Well guys, I FINALLY finished replacing the CV boot (driver's side rear outer) on my UXV 450i last night. It only took me a WEEK to do the two-hour job. That's not bad, right? LOL
So, for your entertainment, here's a little synopsis of my trials and tribulations with this job:
DAY 1:
Order replacement boot and installation kit from eBay.
DAYS 2-3:
Wait for replacement boot to arrive. Replacement boot arrives, only without the installation cone shown in the eBay listing. So, now I have boot and clamps but no way to get boot over CV joint without removing joint from axle. Company says they will send cone, but I don't want to wait for it arrive to get back on the trail. I tell myself I will come up with a Plan B.
Day 4:
Remove the wheel no problem. Next step is to remove castle nut from axle, but realize I do not have a large enough socket for my driver. BTW, in case you ever need to know, it's 30mm.
DAY 5:
Purchase a set of oversized metric sockets at Home Depot for $20.
Now I have the right nut, but no matter how hard I try, I can't get the nut loose. I'm starting to panic. Wondering if its a reverse thread. Call a buddy and borrow his breaker bar with a 3-foot pipe extension. Hook it up, lean into that sucker with all my weight and FINALLY the nut comes loose. Hallelujah!
I get the wheel hub and suspension arm removed no problems. Now I'm ready to install the boot but I still need to come up with Plan B.
DAY 6:
Go to Wal-Mart and but plastic funnel for $1.87. Use hacksaw to cut funnel down where it is just wider than CV join. Lube funnel up with Vaseline, turn CV boot inside out and try to slide it over funnel and onto axle. Man, that back end of the boot just doesn't want to go; I need help!
Yell for my 15-year-old son, tell him to pull on the large end of the boot as it comes over the end of the funnel while I push on the small end with all my might. Finally, POP, it slides over the funnel. It's on! Hallelujah!
I repack the CV joint with grease, move the new boot into position and get the small end clamped onto the axle no problem. While installing the second clamp on the CV join, I accidentally break clamp while trying to cut it. Now I can't finish job...
DAY 7:
Stop at AutoZone and get another set of CV boot clamps for $2.99. Also stop at Home Depot and pick up an adjustable stainless steel snake clamp for $1.64 "just in case."
Go home and try to install last clamp on CV boot and end up breaking this clamp (a different type than the one that came with the replacement boot) too! ARE YOU KIDDING ME?!?!?!?
Tell myself, these things are junk. Get the adjustable clamp, slide it onto boot and tighten. This thing works great! I AM FINALLY DONE!
Put suspension arm, wheel hub, axle nut and wheel back onto machine.
Take several laps around my yard in the dark to celebrate the completion of the project!
Nothing to it, right?
I'm sure no one else has ever had a project go this way - two steps forward and one step back. Anyway, I figured I learned a few things along the way, and even with all the little items I had to buy and the time it took, I'm sure I still ended up saving a bunch compared to what the dealer would have charged me to do in 30 minutes. Next time, I swear it'll go smoother.
