Beck/Arnley inner ball joints for the Koyo rack arrived today.
The major difference is ball ends have different threads and different clip washers.

I don't have the shop manual and have unanswered questions:

What's the best way to get the metal boot clamps off without damaging the boot?
Is there a tool to remove and re-install the metal clamps? Reassembly with metal clamps or use tie wraps, what's best?

How do the washers install, do the tabs fit in holes in the rack ?
I don't see whats going on with those tabbed washers.

The balls have grease, should I put a little never-seez on the threads?

Any other lube or details before reassembly?

Thanks, Bill

Hi,

What's the best way to get the metal boot clamps off without damaging the boot?
Is there a tool to remove and re-install the metal clamps?
-> Use "wire-cutter" pliers to carefully cut the metal clamps off. Don't bite too much into the rubber. Use new metal clamps when installing boots. You could reuse old boots if the rubber still pliant (no cracks).

Reassembly with metal clamps or use tie wraps, what's best?
-> Both almost same result. I prefer to use heavy-duty cable ties to reinstall boots. You could use right-sized jubilee clamps for same purpose provided they're rust resistant ie. automotive grade

How do the washers install, do the tabs fit in holes in the rack ?
-> Yes the tabs fit into hole/indentation in the rack. The tab side should be installed facing the rack.

I don't see whats going on with those tabbed washers.
-> After you have installed the inner tie rod with tab washers, you should lightly hammer the washer so that it locks the tie rod at rack end.

The balls have grease, should I put a little never-seez on the threads?
-> Normally no. Seized thread outside the boot is almost unheard of.

Any other lube or details before reassembly?
-> Yes. Its optional to grease the rack itself. I use BMW steering grease because Volvo grease is hard to find. Fully turn the steering right and left (engine off) to expose the rack and apply grease onto it. This helps to preserve the oil seals so less likely power steering leaks in future.

Amarin.

I am not sure how the small tabs fit, but the edge of the washer bends over the flat on the piece of the tie rod beside it once installed.

You need to replace the boots. You don't want an old one to fail after doing the work to install the new inner tie rod ends.
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Any twenty minute job is just a broken bolt away from a three day ordeal

Will a single tab bent over do the job right?

Thanks, Bill

Yes, one bent over on a flat will prevent the "nut" from being able to move.
--
Any twenty minute job is just a broken bolt away from a three day ordeal