2002 996TT Front Axle Boot Repl. - DIY Project?

[craig.wilson1]

I just bought a 2002 996 Turbo. The PPI identified a few issues, one being a torn CV Boot on one of the front axles. I see from the service history that it had been identified a couple of years back. It's a CA car, so I assume it's unlikely that there has been much deterioration to the CV Joint, but I'm not sure. Before I pay a dealer to replace the CV Joint, just wanted to check to see if this might be a DIY project for someone with 6-7/10 mechanical skills. Is there anything in particular I should be looking at when the boot is off?

Also - are there any "must have" maintenance/repair manuals or websites for someone contemplating doing work on their 996TT?

[shepmess]

I just did this on my 2006 4S. There are some good videos on YouTube that will help. I watched them over and over. Watch all of them and pay attention to the bearing re assembly. You need to line up the inner race up a certain way in order for the bearing to work properly.

You will need a new socket bit for the inner bolts, and I think it is a 12 point star type. You will also need a socket extension to get at the inner bolts. I used one and there was no need to take off the under tray. I bought a 400 lb impact wrench at Harbor Freight. That will save you a ton of trouble with the axle nut.

Get a can of PB Blaster. I needed it to get the axle out of my right from hub. It’s an interference fit and was stuck on there pretty good. Spray all of the nuts and bolts beforehand. The inner bolts that connect to the case are very easy to strip. Make sure to wipe them down before you attempt to take them off and apply plenty of inward/downward pressure.

You have to take the inner bearing off of the shaft in order to get the new boots on. It will most likely come apart and you need to re assemble it. It’s tricky, but not that hard. See YouTube.

Get an Oetiker clamp tool. Some of the new clamps that came with my rebuild kit were not the right size. The large clamp on the inner just wouldn’t fit and I had to go to Napa and get a “cut to size”replacement.

Plenty of paper towels and rubber gloves. You will be dealing with years of grease and grime on most of the parts.

Good luck, it’s not a technical job, just a lot of wrenching!

[craig.wilson1]

Really appreciate the input. Looks like it might be doable, even for me

[Mark44]

Originally Posted by shepmess

You will need a new socket bit for the inner bolts, and I think it is a 12 point star type.

Some of the bolts on Porsche and VW, and likely Mercedes as well, require triple square sockets. You can get a set of these on Amazon or Home Depot and elsewhere for $20 - $25.