Carrera 3.2 CV joint replacement

[Carl Jones]

Hello!

Having a little problem removing the drive shafts.........The transmission end is disconnected no problem. Trouble is, the splines appear to be siezed in the hubs. I haven't pulled them really hard (Yet) but I'm wondering if I'm missing something. I have the factory workshop manual which basically says "Remove the half shafts"! Is there a secondary circlip or nut I need to undo? Please don't tell me I have to remove the entire trailing arm and press out the bearings. Any information most appreciated. Thanks, Carl. (car is a 1987 Carrera 3.2 coupe, G-50 box, non turbo look)

[gr8fl4porsche]

I assume you took off the axle nut?

[Carl Jones]

Yeah, thanks Randy, I thought of that as I posted the message, I didn't make it clear, Yes I did take it off! Carl.

[Rick Lee]

Carl, how did you access the outer bolts - the ones that go to the wheels? Mine are covered by some plate or cup and the bolts aren't exposed.

[Carl Jones]

Hi Richard,

Hmmm, OK, there are no outer bolts (At least, that's what the workshop manaul tells me) I have a Porsche diagram of the assembly and according to that, there are no bolts (I assume you are talking about the 6 INHEX bolts that are the same as what's on the transmission end?)

But, it's wouldn't be the first time I've made a booboo! So I guess my next question is, does an 87 Carrera have 6 bolts on the hub end as well as the transmission end?

Confused in Australia,

Carl.

[gr8fl4porsche]

No bolts on the outer hub. On your '87, only the inner cv joint is serviceable (removeable) from the half shaft. To remove the axle, since you already have it unbolted from the tranny and the axle nut and washer are removed, you may have to tap it a little with a hammer to get it to come out. Have someone else hold the axle while you use the hammer as the half shaft is a little heavy. Do not damage the shaft end - I recommend using a large brass drift or piece of wood.

Good luck - the nasty part comes next when you get to clean and regrease the cv on the wheel side.

[ChrisBennet]

Originally posted by Carl Jones
Hi Richard,

Hmmm, OK, there are no outer bolts (At least, that's what the workshop manaul tells me) I have a Porsche diagram of the assembly and according to that, there are no bolts (I assume you are talking about the 6 INHEX bolts that are the same as what's on the transmission end?)

But, it's wouldn't be the first time I've made a booboo! So I guess my next question is, does an 87 Carrera have 6 bolts on the hub end as well as the transmission end?

Confused in Australia,

Carl.

Carl,
You are correct. Starting sometime in '85 the outer CV changed to one without bolts. You just remove the axle nut pull the axle out of the bearing. I've done 3 axles like this and I think I just gave the end of the axle a little tap with a nonmetal hammer and it popped right out.
-Chris

[Rick Lee]

I don't have my books here at the office, but I thought Bentley's said that the CV axles changed around 1985 or so to fully enclosed or contained assemblies. I thought they just came with the bearings and grease all sealed up and you just had to bolt them in. If they connect with splines on the outer ends, then I'm curious as to how you reconnect them and get the grease to stay in. Someone here has to have some good photos of the '87-'89 Carrera CV axles.

[KTL]

Coat the splines with copper antiseize when you reinstall the shafts.

[Don Plumley]

Richard, I have some pics on my other computer - I'll try to dig them up later. You are right that they changed in 1985. They are serviceable however, not sealed. The inner side has a plate/dustcover that covers the CV next to the drive flange where it bolts up. There is a circlip under the dust cover that holds the axle shaft in the CV. The outer side has the stub axle permanently attached, but once the boot is off the axle shaft slides out and allows you to clean and repack the joint.

Carl, I'm not clear which end you are having trouble with, but the tranny/inner side, you tap off the dust cover to expose the circlip. Mine took a tap or two with a hammer (and wood block) to drop out. Make sure you support the CV well and don't let the other end drop to the floor. For the outer side I seem to recall holding the axle-shaft in a vice and gently tapping on the CV to release the axle-shaft.

Good Luck!

[john walker's workshop]

normally they just slide out of the outer drive flange. some persuasion with a hammer and drift will get them moving. the rear shock has to be disconnected from the swing arm for clearance. if they were knocking, sometimes it's cheaper and easier to replace the complete axle assembly.

[KTL]

I thought the outer, wheel side CV joint is friction welded to the shaft?

I didn't think you could remove the axle shaft from the outer CV joint. Am I mistaken?

[Don Plumley]

{EDIT: remove incorrect information}

And yes, if the joints (especially outer) need to be replaced, just buy new half-shaft assemblies.

[KTL]

So there's nothing fastening the outer CV to the axle shaft?

What keeps the shaft from sliding back and forth within the CV hub?

[Don Plumley]

{EDIT: correct information}

Within the limitations of the cage they slide back and forth a bit. I think that the inner CV allows some movement along the splines, but I don't remember for sure.

[rick-l]

The manual says the axel is friction welded to the joint. I think they spin one piece and press it against the stationary piece to heat it up to weld it.

Cleaning the outer joint is a mess. No wonder a mechanic wants to install a new shaft. What I did was dump solvent into the joint, move the axel in and out of the joint in a washing machine motion to slosh around the sovent, dump it out and reapeat over and over again.

[Don Plumley]

I'm having a serious senior moment. Yes, the axle does not separate from the outer CV. Rick's comments made me remember sloshing the solvent by pumping the axle shaft up and down.

Sorry Kevin!

[KTL]

Right. The overall axle assembly length must change due to the suspension travel.

But, the CV hub and cage assembly pivots back and forth within the CV joint housing. The joint does not slide back and forth on the shaft itself.

The inner joint is fixed in place at each side of the hub by: a) the termination of the axle splines at a shoulder area where the hub butts up against the shoulder, and b) the end of the shaft where a circlip placed in a recess holds the hub in place.

The first picture in Warren's post shows this quite well.

CV joint disassembly

So I still don't see how Don was able to remove the shaft from his outer hub!

Edit: I understand now Don. No problem. I thought I was mistaken about how the outer side is assembled

[Don Plumley]

Cr@p. I hate it when I'm so sure of myself and then the other two brain cells wake up...

[ChrisBennet]

You can service the outer "sealed" joint. Years ago, I dropped an axle off with a friend to have the inner CV joint removed with his press. When I went to pick it up, he had pressed off the outer joint as well. Surprisingly, the circlip was pull through the joint and remained on the shaft.

In order to reassemble the joint, a(nother) friend and I cut the dust cap at the groove/channelure and pulled off the cap. When we were done servicing the joint, we put the cap back on and tapped the edge of the dust cap back into the groove and wrapped it with tape. We used normal duct tape the first time but that melted after one track event. Then we used that shiny aluminum duct tape and that has held up for 3-4 years until the joint itself failed.

I bought a complete new axle for $180 plus shipping so a garage probably pays about the same, maybe a little more. At that price it might not make sense for a garage to clean and repack them.
-Chris