I'd read and been told the originals are not available (or only found in limited numbers) so was trying to find a CV boot which is best shaped to avoid catching on the shock absorber cover...not easy, although there were several possibilities that might work.

The problem with SZ/RZs is the distance between the shock absorber and driveshaft, which is only about 15mm; this means the choice of CV boot cover is very limited.

However, I finally found the right ones...they appear to be exactly the same, are made by a large international company and are freely available for comparatively little money...I bought both CV boots for £45 delivered (€50 at current exchange rates).

For information about inner driveshaft boots click here.

First raise the rear of the car and placed two axle stands for safety.

I also raised the hydraulic suspension first to give more room.

The driveshaft and CV boots...

- Gearbox side

- Wheel side

Using an 8mm allen key or socket, remove the six bolts on the gearbox side.
The driveshaft can be locked using the handbrake or using a screwdriver in the brake disc ventilation holes.

The handbrake will need to be used to lock the wheel side, use the same 8mm allen key or socket.

The joint revealed...

Clean grease away from the middle to find the large circlip

Remove the circlip with circlip pliers.

Remove the retaining clamp for the rubber boot and slide it down the shaft.

Place the CV joint onto the driveshaft, ensuring the marks align correctly and hammer back into position.

Replace the circlip.

Slide the CV cover into position, make sure the holes line up and tap it on.

Pull the rubber part into the lower recess and re-attach the retaining clamp.

This is the boot from the other side of my SZ, the split was even bigger, but in the same area.

Also note, the steel pressing has been deformed in exactly the same place as the cut.

It would appear that some contact has been made between the driveshaft and metal pressing, resulting in the rubber boot becoming damaged. Re-inspection of the first boot also revealed similar signs of deformation, although not as bad.

I wonder how...or why...?

UPDATE 09/06/11 - the boots have now been on my car
for six weeks and over 500 miles, they are working fine!

UPDATE 11/03/12 - the boots have covered around 2,000 miles since fitting and just passed the UK roadworthiness test (MOT).

UPDATE 08/10/12 - another thousand plus miles and no problems. I think it's safe to say the boots are working as they should.

If you wish to purchase a set for yourself simply follow the link below.

Part number required is MS6N001:

108mm Swaged Fast Boot from www.raceparts.co.uk

(Link updated 23/08/15)

At the time of writing they cost £45 for two, including delivery to the UK. Delivery to Europe or the rest of the world is likely to cost more.

Please note, I have no affiliation with the company
and the link is for your information only!

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Additional INNER driveshaft boot information.

The original driveshaft boot is p/n 60728419, shared with the 2.0 and V6 75s. Boots for the 2.0/V6 are still freely available, assuming they fit!

The above part numbers should be the same for the other cars which share the same CV boot, for more information click here to download a detailed "word" file.

If all the above fails (I doubt it!), "The Alfa Workshop" lists p/n 46307475 as a more modern replacement for the inner boot; showing as supplied for the following vehicles:

(ALFAROMEO) - W8 147 BZ/DS (2000-2010)
(ALFAROMEO) - T8 156 TD.ID. (1997-2002)
(ALFAROMEO) - X1 156 M.Y.2002 BZ/DS (2001-2005)

I haven't tested this but have no reason to doubt someone as knowledgeable as Jamie Porter.

Also, www.alfabb.com suggest that Alfa 164 inner boots fit a GTV6 which could be a good enough fit for an ES30, but I haven't made any comparisons yet.

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