[Opie]

Originally Posted by BlkTrax

Went thru something similar with my '02 WRX, Kept blowing front outer boots.

At the time had the Soft Neoprene Rubber outers, basically after getting the brakes hot and speeds over 110 the boots were expanding from centrifugal force and cutting themselves on the strut mount to the knuckles (Feal 441's).

Swapped axles to the OEM style Hard plastic outer axle boots , shaved the bottom strut mounts a touch, and added brake cooling ducting. Never had the Problem again.

You may be able to solve the issue if you can get less heat transfer from the rotors into the axle, and/or duct air to cool the Diff area. Consider, heat is only transferring straight up when standing still, the exhaust route in front of that inner Boot is still basically Hair Dryer blasting that inner boot at speed.

Difference is my issue is the rear left side inner boot only....outer boot (near the brakes) are fine. I can actually touch it after this occurs, and while the outer boot is warm...it doesn't liquify the grease and distort the boot like the inner, the liquefied grease will burn you if you touch it after a session...so I don't think it's a rear brake or bearing issue since it only affects the inner boot.

For reference, the right side (passenger) axle is still the original one an has no issues....left side (drivers) is on the 3rd OEM axle...