I recently bought my s2000 and have driven it for 3000 miles or so (81,000). I started to hear a clicking/popping noise when taking off and sometimes even downshifting under a load. I went ahead and did the TSB the driver side went perfect and when I got to the passenger side it took about an hour to get the nut off. When I took it off the inside of the nut was almost a 1/4 stepped and rounded off inside. I ordered a new axle but when I put the nut back on to get the car back in the garage the whole hub is moving now. Is this a common problem?

Here is a picture of the nut and axle http://imgur.com/a/gGIk6

 

you are suppose to do it with the wheel/tire on the ground

 

I did

 

the whole hub cannot be moving unless the wheel is spinning.

Do you mean that your car is moving when you try and put like 300LB of torque into the axle nut? That's not surprising. You should have the car in 1st gear with the parking brake on.

 

When you say "the whole hub is moving" do you mean that the hub/wheel/tire assembly is rotating clockwise when you apply torque to the axle nut with the socket + breaker bar (or impact gun)?

 

I would avoid putting it in gear.
Instead, I would pull the parking brake all the way up and buy a pair of solid rubber wheel chocks (available from Harbor Freight for about $7/each) and wedge them on both sides of the tire to prevent the the wheel assembly from moving when you apply torque to the wrench / breaker bar.