CV Boot - Never bloody easy

[bmouthboyo]

Hi Guys,

I appologise in advanced for this long post but whilst attempting to do my NS Outer CV Boot on my 1996 Gti, I encountered a number of issues. An I still have the OS Inner CV Boot and OS Steering gaiter to do.

OK Firstly as suggested my CV Joint was seized and as much as I had tried to have all the tools ready I did not have the Hex / Allen bit needed to remove the front caliper in order to use my new puller As it is only the boot that looked knackered I decided to do it with shaft still attached. I removed the lower ball joint (needed replacing) as well as the anti roll bar drop link (needed replacing).

First Issue:

This is my old and new drop link that I bought here:http://www.ebay.co.uk/itm/2-ANTI-ROLLBAR-DROP-LINKS-BUSHES-MK3-GOLF-CORRADO-/390333502162?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item5ae1b092d2





As you can see they are very different sizes. Can I use this new one? If so where can I also get the bolt and nut as the old one is a bit knackered (I do not know the size etc). Is the supplied nut meant to go on the large thread before being screwed into the anti roll bar?

Second Issue:
I purchased a new CV Joint with Boot from here http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=140350408412&ssPageName=STRK:MEWNX:IT

But as mine was seized I thought I would just use the boot etc that came with that one (I know its cheap but only planning on keeping the car another year). However the circlip is too large for my drive shaft. Is it meant to be used on the CV joint shaft and not the drive shaft?:




I am tempted to use the old one but it seems out of shape and when on the shaft I wasn't sure if the gap between the ends was too big?



Third Issue:
When I took the shaft out of the CV joint there was 2 pieces that looked like a washer and a seal. The seal I think was on the shaft like in the pic but I do not know where the metal washer would have gone as it was just loose on the shaft:





So to summarise:
1) Can I use those new droplinks?
2) What size bolt and nut do I need for the droplink?
3) Is the large supplied nut meant to go on the end before being screwed into Anti Roll Bar?
4) What should I do about the circlip being too large?
5) Is the plastic seal on the correct way in the pic? (But inside boot when fitted)
6) Where does the metal washer thing go?

Sorry for such a long post but keeps it tidier than lots of smaller ones. I have looked for hours about for as many answers as I can so please don't think I am being lazy

Cheers

[madmanmart]

I would not use any of them dog sh!t parts but thats just me.

I think that washer goes on first, the the seal thing IIRC.

[dan_apps]

thats the problem with cheap ebay parts, alot of the time not worth it! with the circlip matey i dont think thats gona be a huge issue, im about to do the inner cv boot but as gsf sent me the wrong boot im waiting for a new one to come and cant be of much help here!

[Wayne]

Don't think those droplinks will fit tbh. 

[bmouthboyo]

Well with the nut on the end the drop link resembles the original a little more, but not perfect. The car is on it's way out to be honest and in a year or so I hope to get a MK2 or a Corrado so just looking to get this years ticket.

So far then:

Drop links with nut on will be tested using original bolt and nut. Anyone know where I can get replacement from?

Should I use the original circlip? Do I insert it into the CV Joint already on the shaft in the grove? On youtube video's I have watched the circlip seems to stop teh shaft coming out of the Joint but mine didn't? Just pulled out easily. Is something wrong with it?

Last thing I need advice on then are regarding the plastic and metal washers/seals. The plastic one I am fairly certain is where I have it in the pic. But I have on idea about the metal one. Does it but up to it?

[gasketface]

Take the plastic washer off the shaft and slide on the metal washer which should be a tapered one ?.You should slide that tapered washer onto the shaft so the "high" part of it goes towards the shaft.

The circlip you were given with the kit should be o.k..Just compress it as you push it back into the cv joint.You should feel it click as you push it all the way in.

I think the reason you say you can pull it out easily is because you are trying to push it in with that plastic washer on it and it is'nt going in far enough.I have no idea where that plastic washer came from as i have never seen one on a Golf.

Those drop links will fit,you just need new bolts.They look to be M8 threads so a good hardware shop would sort you.PM me if you get stuck o.k..

[bmouthboyo]

I am a bit confused as to what would be the "high" end on the tapered metal washer. Would it be orientated as in A or B :



I wasn't clear explaining that I think the reason the boot split in the first place was that for some reason when I reversed I could hear a clunk and a very loud whining, almost like the wheel was pulling away the CV joint from the shaft slightly. When going forward there was no issue at all.
I could also pull the Shaft towards the transmission a few inches.

When I took the lower ball joint out so the hub could swing away the drive shaft literally just pulled out with little to no force needed.

Is the shaft meant to be able to be pulled away from the outer joint so easily? If not any ideas why mine did / does?

Also the plastic washer / seal in the pic was definitely on there and I have seen it as part of some kits. It too is tapered. Any ideas what I should do with it?

[madmanmart]

Washer to spec B

[bmouthboyo]

cheers madman.

Anyone have any ideas about the larger plastic washer that I have shown on the shaft? I found a guide for a mk4 here:

http://www.vaglinks.com/Docs/VW/MKIV/UK-MKIVs.net_VW_MKIV_CV_Joint_Boot_DIY.pdf

and it says "Fit the dished washer with the convex side pointing towards the gear box, followed by the thrust washer"

Which is the thrust washer? The metal or larger plastic one? I could have sworn the plastic one was the last to come out (nearest gearbox).

I found this image for a Mk4 also:



Should I install them like that? Metal one first as in B on my crap diagram lol and plastic one after as A in my diagram?

Can anyone advise on the rest. i.e. how it was so easy to pull the shaft out? Do I just push it back in and hope for the best?

[bmouthboyo]

OK today didn't go so well.

I fitted the new anti roll link and that went on fine, new lower ball joint also went on no hitch.

I then fitted the new cv boot with the CV Joint still on the hub as it would not budge at all (2 broken pullers etc etc )

That went on great, my proper CV clamp pliers did the job great, all smiles...

Went to screw on the Hub nut... fubar



I must have damaged the thread when trying to get the b!tch out and it just wont screw on now

I have removed the HUB now and hoping to get it removed at a local garage or engineers (any recommendations on where to go first?).

My question now is is it possible to re thread the CV shaft that the hub nut screws onto? Or could a engineer shop trim it down until it would thread again?I have disassembled the joint and there is no pitting or marks so the joint itself is fine.

I am also now dreading the OS Inner boot I will have to do after all this as the pullers I bought just broke near the hook part, and the inner boot is fine on it so a shame to have to rip the whole HUB off again like this one. Any advice?