Re: CV joint assembly

[steveb@falcon.kla-tencor.com (Steven Buchholz)]

 # I am in the process of replacing the inner cv boot on my '86 5kcs (for
 # the second time in 3 years) only this time, as I disassembled the joint
 # (on my workbench) cleaned the grease out, then attempted to put the
 # joint together again, the Audi gods did not cooperate again with me.  It
 # seems either the joint has miraculously changed in size or there is only
 # 1 way that the joint goes together.  When I put the bearings in, the
 # joint is so tight that is does not move at all.  The bearings are
 # binding with the outer and inner race (the cage is freely moving).  So I
 # am lost!  Any ideas?
 # 
... I'm wondering if you didn't happen to assemble the CVJ incorrectly.  
I don't know if I'm understanding your situation fully, but let me ex-
plain what happened to me.  The grooves in the outer and inner portions 
of the CVJ are not all aligned, but they alternate angles with each 
slot in the joint.  When assembled correctly, each ball slides in a 
groove of one orientation in the inner half and one of the opposite 
orientation in the outer half.  I think this design ensures that the 
balls actually move in the grooves as the CVJ moves in and out.  I 
assembled the joint such that the grooves lined up in the top and 
bottom ... and the joint lock in one place.  It took some doing to 
get it apart, wiggling, twisting, etc. (no hammers), and then I 
assembled it correctly.  The thing has worked fine ever since, and 
AAMOF is installed on the car.

HTH!
Steve Buchholz
San Jose, CA (USA)