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.