Rather than strain my guts or tools when confronted with a rear axle nut that wouldn't come off
when fitting new CV boots (the kits come with a new nut) I did it this way:-
After using a pin punch to de stake the nut I loaded a 1/8" dia parallel carbide rotary file with a radius end in my die grinder (you could use a Dremel) and cut a slot into the hex and back flange of the nut being very careful not to go so deep as to touch the axle or axle thread - this took
about five minutes.
A very slight tap with a chisel to fractionally strain the slot open was all that was then required and the nut
virtually screwed off by hand.
when fitting new CV boots (the kits come with a new nut) I did it this way:-
After using a pin punch to de stake the nut I loaded a 1/8" dia parallel carbide rotary file with a radius end in my die grinder (you could use a Dremel) and cut a slot into the hex and back flange of the nut being very careful not to go so deep as to touch the axle or axle thread - this took
about five minutes.
A very slight tap with a chisel to fractionally strain the slot open was all that was then required and the nut
virtually screwed off by hand.