CV joint servicing / boot replacement

[HAREST@allenbrook.iix.com]

Inners or outers?  FWD makes removal of the axles easier.

Assuming you're going to clean and repack the joints at the same time, its a
dirty job but not horribly difficult.  The first time is the learning curve.
Read the Bentley and pay attention to the pictures and details on how joints
are taken apart and put back together.

Key points to this Chinese puzzle:
inner joints, reassembly:
* races alternate between wide and narrow portions.  match narrow inner with
wide outer and vice versa.
* circlip comes off easiest with a couple of jewelers screwdrivers, but flat
nosed circlip pliers make clip reinstallation easier.  Two Tylenol saver.
* a ziplock bag keeps the new grease from getting contaminated. remove once
axle is positioned, prior to bolting joint to inner flange.
* dished washers install with the cup/concave towards the joint.

outer joint, disassembly:
* joints either have a spring clip or a circlip holding the joint on.
Bentley shows how to identify a circlip.
* with a spring clip: clamp shaft in vice, hold splines of outer joint
inline with shaft, pound joint (outer lip) off using a brass/hard
plastic/wood/leather mallet
* with a circlip: clean access window so you can see the circlip. clamp
shaft in vice. grow third arm. hold outer joint inline. spread circlip.
pound joint off.
** swear and repeat everytime the circlip gets away...
* be careful not to break or lose the plastic thrust washer(?).  Kits don't
include a new one...

outer joint reassembly:
* light coating of grease on (CV) balls makes them easier to assemble
* pay attention to wide/narrow orientation...
* dished washers install with the cup/concave towards the joint.

CV boot clamp installation:
* if you haven't/don't want to purchase a "CV Clamp Crimper" I find that a
set of "nail cut off pliers" or "end-cutters" work well.
** Note: since the two sides of the clamp crimp rarely touch, the cutter
won't cut the clamp.  If you're worried, file the sharp cutting edge and you
have a cheap new tool...


HTH,
-Stott

> -----Original Message-----
> From:	Rob Winchell [SMTP:rbw@avs.com]
> Sent:	Wednesday, July 08, 1998 2:38 PM
> To:	Quattro
> Subject:	4k CV boots gone bad
> 
> Folks -
> 
> Apparently the CV boots on my '87 4k (non-q) are ripped and need to be
> replaced. How gruesome a job is this to do myself?
> 
> Thanks,
> Rob Winchell
> 91 200Q
> 87 4kCS