CV Boot done! Tips I learned...

[MSV96@aol.com]

First of many thanks to all how contributed with CV Boot replacement tips,
help, and advice! With all the information I felt very ready and prepared.

I would like to pass along the things I learned along the way. (All WRT 5ktq
front right axle but applies to most Audis I imagine.)

1. The "triple square bit" is indeed a 10mm. As has been mentioned here many
times, ensure that the hole in the bolt is very clean and the tool bit is
firmly seated. Breaking those free is a bit scary and after all six the tool
was showing signs of wear. (In other words I would suggest owning a spare.)

2. No problem removing the axle (manual trans) with the steering at full
lock--following the instructions of Bentley and others you remove the inner
first and angle the axle up to press out the outer from the wheel bearing.
Remove axle nut with tire on the ground. I used a 1/2" drive 18" breaker bar
and stood on it...loosened right up.

3. One thing that dawned on me, my puller which I have used for pressing out
the outer joints from wheel bearings on 4kqs (I hooked to the lug bolts on the
4kq) didn't quite work out with the 5 lug pattern on the 5ktq. My solution was
to bolt the brake disc securely with all 5 lug bolts and hook the puller to
the brake disc slots (on the hub portion of the disc). Worked great!

4. Removing the outer joint. This is a major PITA! It requires a bench vice
and the circlip needs to be spread open while an assistant beats on the joint
with a hammer and drift. Not fun. We opted for two pair of needle nose pliers
to hold the circlip open. None of my circlip pliers would hold it wothout
slipping. The ideal tool would be one that positvely locks the little sucker
open...dunno if the VAG tool does that but if so would be a huge help.

5. Cleaning and greasing. I had thought about doing the inner and was prepared
with boot kit in hand. Upon close inpection of the boot and the joint I opted
not to. I doubt the inners go bad often. Instead of disassembling the entire
joint I opted (on the advice of a local VW mechanic) to wash out the joint
with fast evaporating degreaser spray. This worked out great since the joint
had never been exposed to water driven grit. This would not be a good idea for
joints with boots which failed in winter I don't think. Once nice and clean I
packed the backside first by working the grease in with my finger (grease is
provided in the Lobro kit). There is also a massive amount of cleaning
required on the inside of the wheel and around the strut and brake caliper
from grease that flew. I was prepared with several cans of spray degreaser and
a roll of "paper shop towels" which all helped.

6. Install joint to axle. Lobro provides a new circlip. Insert that and
carefully start the spline on the axle. Next you pound like crazy with the
axle verticle to seat the sucker home. Took a while with my sand filled
plastic "dead blow" hammer. I suppose one could get aggressive and use a small
sledge but I was chicken.

7. Pack a little fresh grease into the inner. (It was clean but had lost a
little from removal.) I used one of the new slider zipper type gallon freezer
bags to seal the inner joint while installing the axle--worked great!

8. Install outer into wheel bearing. Used a bead of locktight per Bentley.
Used the old axle nut to pull the joint all the way home. Not sure why in
hindsight...I guess I thought at the time that for whatever reason the nut may
need to come back off and I didn't want to waste my new one (also provided in
the Lobro kit).

9. Bolt inner back to transmission. I carefully cleaned the old bolts and
inspected the 12 point inner splines. Bentley did not say to replace these (I
don't think). The inner Lobro kit does contain new ones which are "patchlock"
(blue locktight applied). An assistant here helps to lock the hub with a
prybar against the lug bolts when torquing the bolts.

That's about it...all downhill from there (install wheel and lower from jack-
stands). Torque axle nut (new one) and wheel lug bolts once car is on the
ground.

I hope this experience helps others. The job is really not that bad. After all
was buttoned up a quick spin in my assistant's M3 and a therapeutic evening
sail in a nice easterly breeze really hit the spot (along with a good scrub
and some cold beers). Thanks again for all who posted and wrote private
messages offering help!

Mike Veglia
87 5kcstq