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The boot aren't replaceable, you will need to replace the whole ball joint. If you don't then dirt and water will get into the joint and ruin it anyway and then you will have to replace it.
I'm a mechanic and I almost never replace axle nuts. As long as they torque down correctly and you can stake them they are fine.
I replaced one of mine with a generic ball joint boot from NAPA. My boot was screwed after using the pickle forks to pull the ball joint. I took what was left of the boot to NAPA, the guy took me in the back and I found the closest sized one. It fit very tight around the ball joint stud, and the pressure from mounting it to the spindle pressed the bottom down over the lip where it originally mounted.
 
Stake / Axle & Hub

I'm a mechanic and I almost never replace axle nuts. As long as they torque down correctly and you can stake them they are fine.
Stake them? I'm unfamiliar with this term/idea.

Also, I am having the worst time getting the driver's side axle separated from the hub. Will I be able to just disconnect the axle from the transmission with it still in the hub, or is the removal from the hub a necessary step? It's getting to the point that I'm going to have to destroy the axle to get it out of the hub.
 
What did they charge you for it?

Rock Auto has the ball joint for about $10.
$10 for the ball joint isn't bad, you'd have to pay someone to press the old one out and the new one in with a hydraulic press though. This is probably another $50.

I think the replacement boot was $4.
 
Stake them? I'm unfamiliar with this term/idea.

Also, I am having the worst time getting the driver's side axle separated from the hub. Will I be able to just disconnect the axle from the transmission with it still in the hub, or is the removal from the hub a necessary step? It's getting to the point that I'm going to have to destroy the axle to get it out of the hub.
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Yes, you can pop the axle out of the transmission and leave it in the hub, the only issue is if you have enough room. You could also use one of these to press the axle out of the hub.
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$10 for the ball joint isn't bad, you'd have to pay someone to press the old one out and the new one in with a hydraulic press though. This is probably another $50.

I think the replacement boot was $4.
No need for a hydraulic press. At work we have a ball joint press that is basically a large C-clamp with a bunch of adapters. You put an impact gun on the screw and it presses the old one out and presses the new one in.
 
No need for a hydraulic press. At work we have a ball joint press that is basically a large C-clamp with a bunch of adapters. You put an impact gun on the screw and it presses the old one out and presses the new one in.
Ahh, didn't know about those. Either way he would be paying a shop an additional $50+ to have it pressed in.
 
Ahh, didn't know about those. Either way he would be paying a shop an additional $50+ to have it pressed in.
If a shop quoted you $50 to remove and replace the ball joint on a control arm you brought in then they are a rip off. You could actually buy the tool I mentioned for a not much more. If you brought us the control arm and everything goes well it would probably take 15 minutes or less to swap out the joint and our shop labor is $70 hr. so there is no way you would get charged $50 unless its really stuck.

Of course, the ultimate solution is not to damage the boot/joint in the first place and only use a pickle fork if you intend to replace the part.
 
What socket is needed for the rod bolts (size & type)? I've seen a diverse set of answers on the forum ranging from 12pt, female torx, etc.
It's a female torx, I don't remember the size, but it's whatever equates to a 3/8" socket. That being said, you're either in the wrong thread, or you're messing with something that you don't need to be...
 
Stake them? I'm unfamiliar with this term/idea.

Also, I am having the worst time getting the driver's side axle separated from the hub. Will I be able to just disconnect the axle from the transmission with it still in the hub, or is the removal from the hub a necessary step? It's getting to the point that I'm going to have to destroy the axle to get it out of the hub.
I am working on my second swap, and I have done both of them without removing the axle from the hub. Loosen the strut bolt and drop the hub off of the strut (or beat it off in most cases lol), and then the hub will move enough to disconnect the axle from the transmission and move it off to the side for the remainder of the process
 
I guess I got spoiled with a Florida car! My driver's side slid out of the hub no problem, and hung out of the transmission during the pull. The passenger side stayed in the hub, and slid out of the intermediate shaft. No issues whatsoever removing axles from hub and I-shaft. It is, however, a serious pain in the ass to remove axles from the transmission, as by design, they have locking clips that are hell to remove. Takes a considerable amount of force to break the tension, which is tricky, since the axle joints float by design.
 
It is, however, a serious pain in the ass to remove axles from the transmission, as by design, they have locking clips that are hell to remove. Takes a considerable amount of force to break the tension, which is tricky, since the axle joints float by design.
At work I usually pry between the CV joint and trans case and they pop right out, not difficult at all.
 
I ended up leaving the drivers side axle in place, I pried and pried and it wouldn't come out. Pulled the engine with it hanging.
 
Axles finally out

I was able to pry the DS axle out from above with help from the engine. The PS axle was not coming out though, so I grabbed a hammer.
I expected the PS axle to look like the DS axle, but maybe since there's an intermediate axle, it doesn't? Here's the PS axle: Did I screw up, or is this right?
 

Attachments

The passenger's side is designed differently because of the intermediate shaft. I'm not really sure what you're asking though.
 
Ohh, no. That's just the way it's designed. You did tear up that metal lip pretty badly though. I'm not exactly sure what it does, probably helps to seal the splines from dirt and water contamination.
 
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