I guess axle rebuilds are one of those projects that build character. I feel great that I know how to do it now, but I hope I never have to do it again.

The axles and boots on this car looked great, but they had to be rebuilt. I have a new (used) 3.91 LSD from a 320i. In order to swap in this rear I needed to install 320i CV joints on the inboard ends of the axles. While I had them apart I figured I should clean everything up and replace all four boots.

The axles, and the whole rear of the car for that matter, were caked with mud. A scraper and some parts cleaner took care of that problem.

Here's a shot of the inner workings of the 320i CV joint.

To do this project you need two key tools. First, a press to remove and reinstall the CV joints. My brother and I have a 20 ton press from Harbor Freight that works great. Money well spent. The second tool I needed was a CV boot clamp crimper. Here's a shot of the one I borrowed from my brother.

I got the new boots from Bavarian Autosport (part# 33 21 1 207 036.) They came with the boots, clamps, grease, and a new C-clip for the end of the axle. I must've gone through a dozen pairs of medical gloves disassembling and repacking these joints.

Here is a shot of the final product. Notice the difference in the CVs. I also painted the axles, but found that it's almost impossible to reassemble these things without scratching the new paint.

Here's a closeup of the joints. The 320i on the left and the 2002 on the right.

I hope these things are right. I never want to take them apart again.

The next step is to rebuild the rear subframe and install the 3.91. Then I have to order a set of spacers from Ireland Engineering. The new rear is narrower than the original, so spacers are needed to make up the difference.