CV Axle Replacement
A month ago, if someone had told me I was going to install coilovers and replace CV axles, I would have said "Hahahahahah no."
But these cars do something to you. Faced with a failed outer CV boot and cracked inner CV boots on both sides, and the CV joint grinding, I realized that I was either going to do it or pay to have someone do it. So I got it done. It look much longer than I would have liked, consuming three evenings after work, but I learned a lot and I bought some more tools. It's a job that a determined rookie with some basic background in wrenching can do, and it's a shitload better than paying hundreds of dollars to have it done.
I got a pair of TrakMotive CV axles (Tecker recommended!) from Rock Auto for $55 each plus shipping if you expedite them.
Things you will need:
Metric Socket Set
30mm Axle Nut Socket
Impact Wrench
Breaker Bar
8mm Hex Socket
Tie Rod Remover (you might be able to get away without one--I didn't need it for one, but needed it for the other)
Extension (if you go with the impact wrench method of removing the hex bolts from the CV axle)
General tools like hammers and pliers and such
My recommended order of operations:
0. The day before, apply penetrating oil to the CV axle nut, the castle nut at the tie rod, strut bolts, caliper bolts, and the hex bolts attaching the CV axles to the transmission.
1. While the car is on ramps and chocked, with 8mm hex socket remove the 6 hex bolts (which should be at 48 foot pounds torque) attaching the existing CV axles to the transmission. Alternately, this can be done later with an impact wrench and an extension, like this:
2. Remove the CV axle nut from the center of the rotor--an impact wrench is very helpful for this.
3. Loosen the tie rod castle nut and remove the tie rod end (you may need a tie rod remover).
4. Remove caliper and place on bucket or hang from strut spring (I found this better).
5. Remove strut bolts.
6. Swing axle assembly out and remove old CV axle.
7. Apply grease generously to new CV axle inner gearing.
8. Insert outer CV axle into wheel bearing (outboard hub), hand tightening new (or old) CV axle nut.
9. Replace and tighten strut bolts, tie rod castle nut, and replace caliper on knuckle and rotor.
10. Hand tighten hex bolts securing CV axle to the transmission.
11. Put tires back on without center hub cap and secure with three hand tightened lug nuts, then drop the car.
12. Tighten CV axle nut with breaker bar while tires are chocked, being watchful to locate the cotter pin hole where there is a gap if you use the new CV axle nut provided.
13. Jack car back up, remove tires, put the hub cap back on.
14. Insert and set cotter pin in CV axle nut.
15. Tires back on.
16. Get car up on ramps, chock, use torque wrench to tighten CV axle hex bolts to 48 foot pounds of torque.
I found the overall experience affirming, because in my growing opinion, to own and operate an AllTrac or GT-Four is to be both a driver and a technician. Unless you either want to eventually just have a garage or lawn ornament, or you have inordinately deep pockets for mechanics' charges.