Flexx Boot Axle Repair Using Cone - PeachParts Mercedes-Benz Forum

tobybul · #1 04-24-2009, 09:17 PM

Ok here it is. It was not as difficult as I imagined. As mentioned in a previous thread, the GSP axles I just put in were not any good

and am not about to experiment and replace them with replacement GSPs since the job is not exactly a snap to do.

So here's how I did the flex boot work.

First I unfastened the oe straps off the boots. Then I slid out the old boots from the can and poured the gear oil out of it (have a container handy for the used oil). Each axle end took about 1/2 pint since both axle assemblies took a total of 1 qt.

Then I sprayed the inside of each axle with brake cleaner. Afterwhich, I cleaned it off with compressed air and poured a few drops of oil back in to it just to keep it lubricated.

I did not cut out the old boots yet. I kept them in the shaft since I was not sure how well the manual flexx boot installation would go.

Next, the Flexx boot installation process.

Soaked flexx boot and cone in hot tap water for about 3 minutes

Used Pledge to spray cone and boots to ease sliding. I inverted the boot inside out.

Could not take pic of boot on cone since I was by myself but heres the boot already on the axle. I had the axle resting on the table on a vertical position. It took some effort but but not too bad. Used paper towel and rag to hold and pull boot down. As a precaution, note that I did not cut out the old boots until I was sure I could put in the new boots.

I had to try it 2X for each boot to slip thru. It pretty much pops right thru.

Another view

I inverted the boot right side out and cut the excess piece.

After removing the old boots, draining the old oil out, shoving in the new boots and correctly fitting the new boots (trimming unneeded rubber) on the axle, position the axle so it is standing standing upright on a work surface. Do not clamp the new boots yet. Push it out of the way. Get the large and small clamps ready.

With the axle upright, fill the lower axle with new oil. IIRC, it took 1/2 pint or up to about half an inch filled over the gear. Once filled, reposition the boots on the axle.

Install the large clamp and the small clamp. Do not overtighten so you won't tear the boot. This completes one end.

Repeat the procedure to do the other end. I recall that all 4 axle ends took a total of 1 qt.

Heres the boot installed, the old boot and the strap fastening tool. The rings around the shaft are part of the old boots. Each boot had a ring inside which kept the rubber boot round. I made sure that I fastened all the new straps to the new boots before cutting out the old boots.

Final product and the stuff I used.

All in all, it probably took me about an hour to do both axles. And thats taking my time doing it.

Yes, Henrietta, there is gear oil inside those cans. Now lets see how long they stay there.

running-snail · #2 04-24-2009, 09:26 PM

Nice job documenting this process with pics! I haven't studied posts on the process but one of my axle's boots have what looks like deep cracks along the ridges. I should probably do this while I still can...

Thanks again for all of your write-ups recently - very helpful.

Brian Carlton · #3 04-24-2009, 09:27 PM

That's some good work. If the axles are in good condition, the cost to do that job is minimal as compared to getting replacements.

Where did you get that cone? Is it available online or from a McParts?

tobybul · #4 04-24-2009, 09:51 PM

Quote:

Originally Posted by Brian Carlton

That's some good work. If the axles are in good condition, the cost to do that job is minimal as compared to getting replacements.

Where did you get that cone? Is it available online or from a McParts?

I got it from Astoria along with the boots, straps and tool. They were the ones who suggested soaking hot tap water and spraying pledge.

Edit/update:

I mentioned this on a later post but i ended removing the astoria boots and used Dorman boots instead. The astorias gave excess rubber accordioning which resulted into it getting pinched when reinstalling the axles. The Dormans are also a bit more sturdy. They did require more effort to slide in but not bad.

Brian Carlton · #5 04-24-2009, 09:54 PM

Quote:

Originally Posted by tobybul

I got it from Astoria along with the boots, straps and tool. They were the ones who suggested soaking hot tap water and spraying pledge.

Since you'll never use the tool again, you might want to put it in the rental program..........or an ongoing sale program.

Diesel911 · #6 04-25-2009, 01:25 AM

Quote:

Originally Posted by Brian Carlton

Since you'll never use the tool again, you might want to put it in the rental program..........or an ongoing sale program.

Or, you could give use that part numbar and price!

tobybul · #7 04-25-2009, 01:43 AM

Quote:

Originally Posted by Diesel911

Or, you could give use that part numbar and price!

Flexx Boot 3000 (includes strap and grease) $17 each
Strap Fastener tool $20
Cone $20
http://www.astoria2000.com/

Valvoline Durablend 80W90 oil $6.99 AZ
Pledge $???

As far as I know, Fastlane does not sell the Flexx Boot.

DeliveryValve · #8 04-25-2009, 01:44 AM

Great job. Thanks for sharing.

Regarding the GSP axles, are you sure you used the correct size spacer? I think I read somewhere the GSP axles does not take the original spacers.

pawoSD · #9 04-25-2009, 01:58 AM

I too will be doing this soon....we'll see how it goes!

pawoSD · #10 04-29-2009, 10:46 AM

I guess the key is to be super careful.....I just ordered 8 boots last night.

And a bunch of other parts. We should be ready to do this on both cars by sometime next week!

79Mercy · #11 04-29-2009, 11:08 AM

I also need to do this. My axles are still good but the boots look aged.

How much grease should be put in the boots?

mplafleur · #12 04-29-2009, 01:21 PM

I think they are going to get a fair amount of business from this forum.

bgkast · #13 04-29-2009, 03:43 PM

I'll be interested to see how the gear oil works out. It seems to me like it has the potential to leak out through the clamps too easily leaving the joint dry.

Diesel911 · #14 04-29-2009, 10:32 PM

Has anyone posted the Part Number for the Dorman Boots?

turbobenz · #15 04-29-2009, 10:48 PM

IMO, using gear oil in axle boots is asking for trouble. If it was better than grease, Mercedes and every other car manufacturer would use oil instead of grease. A century of engineering says use grease, not oil.