I'm sure this is posted somewhere, and I'm probably waisting my time, but here it goes anyways. The main reason for posting this, is due to all the questions pertaining to it. Its very simple with the right tools, and a little instruction. Upon checking out my sons 300 and doing some regular maintenance, I noticed he busted a boot last weekend while riding. I did this last night and from start to finish, even with taken pics, it took me right at 30 mins. I've done several, so the time it takes you may or may not take longer.
Tools I use:
Ratchet, banding tool (You can get this from any CV store for about 25 bucks)
2 long bands (Get these at any CV store about .75 each
2 short bands (Same as above)
2 cv boots (Same as above, usually about 4 bucks)
Dremel with cut off wheel,band cutter, or side cutters. Either will do.
Snap ring pliers
Assuming your bike is jacked up, and wheel remeoved, this is what I do.
1)Remove cotter pin, and large axle keep nut or hub nut. Its sometimes called the castle or crown nut also.
(Be sure your diff oil is drained)
2) Remove upper upper shock mount bolt
3) Remove upper A arm bolts (See pic bellow)
4) Remove lower A arm bolts ( all the above may vary, but still the same concept. You may have to remove boot guards or other bolts that are in the way)
5) Grab the axle with your strong hand..LOL and push inward toward the diff. The inside cage of the joint will slide inward. This will allow you some room for levereage
6) Yank on the axle arm (this may take several tries, push the axle inward toward the diff again and repeat) The axle will pop out of the diff.
7) With the axle out of the diff, use a rubber mallet,wood block, or thread the castle nut back on to the end of the axle and tap it until the axle is free of the hub. DONT LOOSE THE RUBBER BUSHING ON THE HUB
8)Now with the axle in your hand, cut all the bands off. You can purchase a band cutter at any auto parts store,use a good pair of side cutter, or use a dremel with a cut off wheel, which is what I use.
ATTENTION***** When cutting the band off of the torn boot, you can go crazy and cut it howeer you like! BUT!!! on the boot that is still good, just cut the band where, the tab is, and only cut the tab. Dont go all the way through the entire band, as it will cut into the boot when using a dremel. If you're using a band cutter,or side cutters, just cut the whole band. You may have to use a flat head screw driver to pry up the band first. be careful not to puncture the good boot.
9) With bands cut, slide the inboard boot (boot closest to diff) down the axle toward the outboard boot. ( You may have to use a small flat head screw driver to free it from its position)
10) There is a large C clip inside the inboard joint,just beneath the lips of the joint. This is what keeps the joint from sliding off. You will see notches cut out of the lip. This is to gain acces to the C clip. Use a very small flat head screw driver, and pick out one of those grooves, to try and pry the screw driver in between the lip of the joint and the C clip. I always do this until I find the end of the C clip. The end is much easier to pry, as it has the least amount of tension on it. The clip comes out pretty easy, just dont loose it. Also you will need to take a pretty sharp angle on the clip to get it out. Be sure and push the axle in toward the cup. (The race will slide in giving you room to work, just like when pulling the axle from the actual diff in step 5)
11) With Clip removed the joint will now slide off.
12) Now you see the cage, that has the balls on it. Clean as much of the grease as possible, away from the top part of the cage.
13) You will see a snap ring. This part can be a little tricky but not bad. It also gets a little messy here for me.
What I do is take my snap ring pliers,and spread the snap ring. With my other hand, I grap the cage, and lift up, using the weight of the axle to make it slide out of the cage. The snap ring pliers can be a PITA, and will keep coming out, which is why I do it this way. Works like a charm.
14) Remove the cage with race
15) Remove the inboard boot
16) Remove the Outboard boot
17) Clean neccisary parts
18) Install new outboard boot
19) Install new inboard boot.
20) Regrease both joints and put a decent amount inside the boots.
21) Position the new boots in the right place, and clean outter part if neccesary.
22) Place your bands on new boots, and tighten the up.
23) Now reverse your steps to install the axle and suspension parts. Dont forget to fill your diff up.
Hope this helps!