All, this is really about my 1998 c70, but the front half is identical to a S70 T5 Turbo.

A month or two ago, I discovered that there was a substantial crack in the outer CV boot on the passenger side and a dime-sized hole in the inner boot. Unfortunately, the work I had to do to the engine (head gasket) took precedence and I only just got to the axle this past weekend.

I ordered the proper boot kits from FCP (EMPI brand) to make a proper repair (The axle never got to the "clicking" stage) To give me time to make the repairs, I swapped on a no-name aftermarket axle. I don't expect this "new" axle to last, so I went to work on cleaning and re-booting the beefier original axle (which seems to be EMPI brand).

Here's where the issue come in... The outer boot was easy - very straightforward. A nice and tight fit. The inner boot is another story.

The part numbers check out (86-2188-D), but the big-end of the inner boot is not tight. I wasted one of the clamps from another kit trying to get it to clamp down before I managed to get it tight enough using zip ties before installing the clamp. It might snug enough to stay put... I'm not 100% sure that this thing is going to stay in place. I don't get how the correct part number-boot would fit so badly.

Now that I've cleaned and re-greased the whole axle, I'd like to put it back into the car, but I'm worried that the inner boot will just pop loose once I start driving it.

Has anyone had this issue? Is there any chance that this is the wrong boot in the box?