Re: help...tear in cv joint boot

[Dave Conner <conner@cfm.ohio-state.edu>]

At 05:36 PM 11/1/1998 ,  J S was inspired to say:
>  I have a small tear in my front boot and just ordered  replacement.  
> Any advice or BTDT?  
>  thanks in advance,
>  John
>  90quattro20v

I've just finished replacing CV boots on two different cars, 86 4kq and 89
100, and have some BTDT to share.

1.   There has been recent discussion re: replacing differential axle shaft
seals.  If you already have the axle shaft off, this is the time to replace
that seal.  You've already done 90% of the work required to get at it.  You
might want to do it as preventive maintenance.

2.  If you dis-assemble the CV joint itself...be very careful to make sure
you put it back together correctly.  It seems they can be assembled in more
than one way, but only one will work.  They can be a real puzzle to put
back together.  

3.  You >may< be able to avoid dis-assembly of the joint.  Someone
suggested using brake cleaner to flush out the old grease,  Then just
re-pack it with new grease.
The down side is you don't get to inspect the innards.  But the good part
would be you don't have to spend a lot of time fiddling with the pieces to
make sure you have put it back together correctly.  If replacing both the
inner and outer boot...it is possible to slide both boots on from one end.
On my 89 100 I removed only the inner joint and slid the new outer boot on
from the inner end.  This was because the #%*@!** circlip for the outer
joint broke and I could not get it off no matter how I struggled with it.  
You may want to flush the old grease off with brake cleaner even if you
will disassemble the joint because then you will be able to see what you're
doing...the grease is such a god-awful mess.

4.  The Bentley states you >must< mark the pieces before dis-assembly of
the inner joint as their orientation must remain the same after
re-assembly.  They suggest  making this mark with a grinding wheel because
the parts are too hard for other tools.  If you fail to mark it first you
>may< be able to discern a wear pattern that will allow correct re-assembly.
 
HTH,
Dave Conner
Columbus, OH 

87 5KS
89 100E
86 4KCSQ
91 200Q Avant (For Sale)