Subject: cv boot replacement 86 5kt

[Beatty, Robert]

-----Original Message-----
From: Christopher Ritchie [mailto:critchie1 at hotmail.com]


Jay Dias wrote:
Looking for BTDT info, do have bentley. Boot is LH side outer
(near wheel).


1. The Audi cv kit is cheap - ~$10.  It contains everything you need - boot,

circlips, grease, axle nut.
2. You need a big socket to get the axle nut off - 23 or 32 mm - i.e. one 
that doesn't come in the usual socket set.  When you get this big, you may 
find that a socket size in inches and fractions fits well.  You'll also need

a big breaker bar and/or pipe extension to get the axle nut off and on.  
Look at the Bentley for torque values.


I believe the american conversion is 1 1/4 or 1 1/8 cant quite remember, but
it does work.



3.  You'll need "triple square" sockets to get the axle shaft off at the 
transmission end.  Hex and torx keys do not fit.  Clean the cavity well 
before inserting the tool.
4.  You'll need those special opposite pliers with the tips (I forget their 
name.) to hold the clip open while you pound the hell out of the joint to 
get it off the shaft.

Snap ring pliers.....

5.  You'll need to pound the hell out of the joint where it is pressed onto 
the shaft.  (This bears repeating.)

there are 2 methods to doing this.  1st method involves separating the outer
joint from the shaft which will require alot of pounding (as previously
stated).

The 2nd method is to support the inner joint with the shaft free so you can
pound the shaft and the outer joint off as one assembly.  Its easier to do
and less risk of damaging the joint as you are pounding directly on the
shaft instead of the joint as you would be in method one.  After removing
the snap ring on the inner joint, place a large socket or suitable piece of
metal ontop of the shaft and pound it out.  Cut off the old boot from the
outer joint after you have it and the shaft off the inner.  Clean the entire
joint out... completely!  I used brake cleaner as it leaves no residue and
wasnt as dangerous as gasoline.  After the joint is dry, you can slide the
boot down over the shaft and onto the outer joint.  Its rubber so it will
stretch over the 2 metal rings 1/2 down the shaft.  Fill the joint with
grease, USE THE WHOLE PACKET.  Squirt it into the joint untill it comes out
the gaps then put the rest in the boot.  Clamp the boot down with the metal
ring.... and re install in car.


6.  You'll need some way to squeeze the bands that hold the rubber boot on 
the shaft.

Usually wire cutters (dikes) work just fine for this


7.  The special grease that comes with the kit stains.
8.  You can buy rebuilt axle shafts.
9.  Do not move the car, even by rolling it, with the axle shaft out.  
You'll ruin a bearing in there.