The outer boot on my driver's side rear axle is torn, needing repair. From what I've read the best solution is to replace the whole axle with a remanfactured or used axle. I've done most replacements on the car (clutch, alternator, starter, rotors, etc...) but not this.

How hard is this
What tools will I need
What are good (or bad) sources for a reman or used axle.

Thanks

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Josh
'81 240 d manual

Is the axle making noise? If not, look for an aftermarket split boot to replace the old one. Just remember to repack the joint with good quality grease.

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'82 300D Turbo 216k miles

Guys - I made the rounds on this one a couple of years ago and could not find a split boot for a 240. There are lots of split boots out there for other models.
I also heard over and over that split boots are no good. I do remember using split boots on VW axles way back in the past somewhere and not having any trouble, for as long as I had the car anyway.
With many axles you can undo a clip on the axle shaft and take off the inner cv joint and slide the boots off and replace them, but not with this axle.
I was surprised to find no one in the Athens Ga area, including the Mercedes dealer, who was able to renew the boots.
So, I went with a rebuilt axle with new boots and a lifetime warranty.
It isn't difficult to change out the axle but you do have to drain the differential and undo a plate to get to some clips that let you withdraw the axle from the differential.
You could check the parts shop on this site for an axle. Also call your local dealer and see what their take on boot replacement is. The dealership here has some nice people but I wouldn't accuse any of them of being exactly cutting edge on tech stuff.

No special tools needed. A Haynes manual explains it well enough.
Good luck and ask around some more,
Harvey

I agree with the above comments about split boots. When I was a poor student and had my 81 240D, I replaced a cracked boot with a boot from another w123 from a junk yard. I found a boot that was in good shape and cut it off. I cleaned the joint in my car and repacked it with grease and super glued the boot from the junk yard on to the axle shaft. It held up for more than a year and I never heard any clunking noises. If money is no problem, rebuilt or used axles are the cheapest way to go. My brother had reman units put on his 240D for $700.

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'82 300D Turbo 216k miles

You sure have to watch these 240D rear axles. The problem is these cars have so much brute horsepower, those axles get trashed in a hurry.

Seriously though, this is the only trouble I've ever seen or heard of regarding 240D axles. I guess enough years have gone by now, that just plain age and rot is finally getting them.

Putting 67 horsepower in a chassis designed for three times that has some advantages.

Have a great day,

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Larry Bible
'84 Euro 240D, 523K miles
'88 300E 5 Speed
'81 300D Daughter's Car
Over 800,000 miles in
Mercedes automobiles