I just installed this SURTRACK/TRAKMOTIVE front CV axle on my 2006 530xi. Mfg part number: BM8041, OE part number: 31607570275.
It doesn't seem to fit properly. I feel like this boot will tear within a few miles with how creased and deformed it is (it is fully installed in these images)
Since this isn't a super quick job, I just want to make sure I'm not being paranoid here. I should return this, right?
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It appears that it was pinched or damaged at some point during the packing or shipping process. I have also done this and, as you said, it's not a ten minute job. I would ensure the boots are properly fitted.
Also, make sure that your axles are snapped in - you should've felt and heard a click after some resistance as the ring seated itself.
The boot actually looks fine when it's not installed. It's like the boot is just can't extend like it should, like it's too short or attached to far away from the joint, so it just buckles.
I've ordered some GTK replacements.
Oh, and it definitely clicked... getting this new one out off the diff is much more difficult to do than the original. The metal on the inner joint is pretty soft, to whacking it with a punch I have mostly just dents the metal; I'll need to get a fatter punch to do the job.
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