Tip for changing rubber drive shaft gaiter
I noted you will have to change a CV joint (unfortunately an expensive business). Remember a tip to avoid a worn rubber gaiter in no time:
after replacing the outer joint and its gaiter, make absolutely sure that you do not leave either too much air in or a vacuum inside the joint. To avoid this before refitting the drive shaft to the car, insert very carefully a blunt screwdriver under the narrow neck of the gaiter (with the small circlip still loose) while moving the outer joint in all directions. This will equilibrate the internal pressure with the external one and ensure a long life to your driveshaft. Tighten the circlip.(I imply that you know how to change a CV joint).
- Andrea -

Q: Is it possible to change the outer CV boot (gaiter) with out removing the axle nut, I do not have the factory tool to do this. I could release the axle at the transaxle and proceed from there.

A: I don't think you can replace the outer CV joint gaiter without undoing the axle multi-slotted nut. You can have the tool made by any competent machine shop if you take a careful template of the nut. Alternatively, these tools are normally available through specialist suppliers such as Omicron. Just make sure that you order the correct tool with the right shape.
- Andrea -

Q: I have borrowed a tool to remove the six point outer retaining lock nut for the front axle. I am going to replace the outer CV rubber boot. I have a original style boot to use, but last night I noticed the passenger side outer boot is tearing now also. I am thinking that maybe the Fulvia would benefit from a more modern CV boot, one that has different rubber and construction to allow the boot itself to flex easier. What do you think? Will I have to remove the axle from the transmission to redo the outer boot?

A: Read my tips above and you will avoid trouble. You might search and find a suitable rubber gaiter which can replace the original Lancia one. They rarely fail if properly fitted. The driveshaft will have to be pulled out from the gearbox to change the outer CV gaiter. Then you remove the inner CV joint and finally the outer gaiter. Leaving the driveshaft in place is not incompatible with changing the outer gaiter but the danger of damaging components is very high because you will have to knock the outer CV joint out.
- Andrea -

Q: How difficult is changing the CV boots. I have an outer that is torn and requires replacement. Special tools?

A: Changing the gaiters (boots) of CV joints is tricky but not difficult ONLY IF you have the correct tools to dismantle the driveshaft nuts (which are torqued up to a very high value). If the tools are not available, you must have someone to make them for you with very, very strong (hardened) steel.
Basically what you do is to remove the wheel, undo the driveshaft castellated nuts with trhe special tools, undo all bolts fixing the inner CV joint to the gearbox, with the help of a puller after having moved the inner CV joint sideways you then push in the driveshaft (plus joints) which can now be removed from the car. Take out the inner CV joint after having removed the circlip which fixes it to the driveshaft (fiddly job) and the inner CV joint boot. At this stage you can simply slide out the bad outer boot and replace it with a new one making sure that the gaiter clip can clear the bolt on the suspension (do not use worm roller clips). Make sure that fresh, special grease is re-applied to the joints and that inside the boots there is no negative or positive pressure otherwise they will not last long (see above).
- Andrea -