Crager,

Didn't you move at about the same time as the boot replacement? I'm only asking because the fuel "winter mix" is state regulated, not Federal. You may be experiencing a worse mix than you've been used to in the past (more ethenol).

I'm assuming that you followed the boot install instructions posted here so you didn't pull the shafts out of the axle tubes. True?

What kind of boots did you install?

When I put on MechaTechs, it seemed to me that they only provided about half the amount of grease that you should be putting in (IMHO). The good news is that you don't need to tear it all the way down again if that's the problem. Just cut the large band off of each boot and pull it back to schlep some high quality synthetic grease in there & then replace the band. Careful cutting the band tho ... don't damage the boot.