Reconstructing Constant Velocity (CV) Joints

[rcecale]

Okay, fellas, Sunday School is over!

Now, getting this thread back on-topic....

Just placed my order with Glenn at Pelican. going with the following:

- 4 Boot Kits for re-doing the boots on both ends of BOTH axles. P/N: F-332-924-02

- 24 new cap-screws, P/N: 900-067-123-01

- 24 new Schnorr Washers, P/N: 999-523-103-01

- 12 new Moon Clips, P/N: 911-332-191-00

A big "Thank you!" out to Randy Webb for this thread. It proved to be a valuable resource for locating the proper part number for the Schnorr Washers. Also just a great thread that should help with refreshing of my axles.

Randy

[pwd72s]

Good news Randy...let us know when you're running again. Big chill & Ron? Sometimes, just sometimes, I miss the smell of the incense...

[rcecale]

Originally posted by randywebb
Thanks - glad it helped!

Send your beer keg donations to me in greater metro Nimrod, Oregon at 666 Twisty Lane. We have a suite on the 75th floor of the Trans-Orygun Bldg.

Randy,

Do you have a PLAY-pal account?

Randy

[rcecale]

Okay, now it's starting to get real interesting.

Decided earlier today that since I was installing new Boot Kits on the inboard ends of the axles, I may as well do the outboards too. Went out to the garage a bit ago and was instantly stymied.

My question here is, do I need to remove the tires and brakes and stuff to get to the bolts for the outboards, or can I just move/slide that cap along the axle shaft to get to the cap screw heads. Don't want to force anything and mess it up.

I suppose I could spring for a Bentley's about right now, but then what would that do for sharing this information with everyone else?

Randy

[rcecale]

Found this pic on the WWW.


Looks as though I should have access to the cap screws on both ends. I'll go out and have a closer look-see. I'll take my trusty camera with me too.

Randy

[rcecale]

Well, that didn't take long. Here's what I found.

Passenger Side - Outboard, with boot pulled away.


Passenger Side - Inboard


Driver Side - Inboard


Driver Side - Outboard


There certainly doesn't seem to be access to any cap screws on the outboard ends. Am I not tearing into this far enough from underneath? Or do the wheels and brake assemblies need to come off to allow access?

Randy

[Beethoven]

There goes Randy again with his stunning photography--notice the deliciously placed red object to give the composition just the right kind of contour? The Cartier-Bresson of garage photography!

[rcecale]

Beethoven, are you trying to tell me something???


"Arizona" Henri Cartier-Bresson, 1947

Randy

[bigchillcar]

The Cartier-Bresson of garage photography!

hilarious, beethoven! you can't hear, but great eyes..very good show..
ryan

[randywebb]

I think people with 'new' cars - like yours - have to pull the whole axle. Earlier cars, up thru the SC (?) don't. My basis for this is seeing a lot of posts with Carrera owners cursing about the 300+ ft-lbs on the wheel nut...

You DO need a Bentley - false economy not to have one.

Good Luck.

[rcecale]

Okay, not sure why I didn't think of this before, but replacing the CV joints is Project 41 in Wayne's 101 Projects book.

Read through that and found the answer I was looking for on Pg. 115.

"On these later cars, the outer CV joint is not available seperately, but must be purchased as a complete axle. This is because the joint is integrated into the stub axle and cannot be separated."

Looks like I ordered the wrong stuff. Putting a call into Pelican tomorrow to change it. Hopefully they haven't shipped it yet. Haven't received the e-mail yet, so....

Randy

[rcecale]

Thanks, Randy!

Would you happen to know off hand what the size of the wheel nut is?

Randy

[randywebb]

No, I have a '73. But it's big - maybe it is on the Pelican parts diagram in the catalog? If you are dying to work on it this weekend and can't find it, re-post by Sat am and I'll look in the copy of the PET (something else worth your $15).

Want to change the title of this thread so folks can find it easier with the search function?

Best, - Randy

[rcecale]

Randy,

Changing the name would be a great idea. Perhaps something like "Constant Velocity (CV) Joint Replacement"? Moderators????

I'd love to work on this over the weekend. Any info you can provide will be greatly appreciated. I check-in here several times through the day, every day, just to keep up with everything.

As it stands now, I have two threads on the tranny flange that need to be chased. I'll probably end up doing them all, just because. If I can get the axles off too, that would be great.

Glenn at Pelican said my order should be here in 4 - 5 days, so that gives me a week to get everything apart and cleaned up. Hopefully I can catch them first thing in the AM, before they ship anything. Think I'll be going with two new axles, rather than the kits I ordered.

Thanks, again!

Randy

[rcecale]

Found this article during my searches. Just might come in handy.

Remove the cotter pin (non Carrera) and the axle nut. On a non Carrera car you'll be OK with 1/2" drive breaker bar and socket (30mm) but on a Carrera you'll need 3/4" drive (and 32mm socket) because of greater torque on the nut.

Randy

[Grady Clay]

Randy,

You might do a price comparison between the Carrera axle with the friction welded stub axle and the Turbo axle that bolts onto a separate stub axle. I think the latter is more serviceable in the long run. The issue is cost difference.

Unless I’m missing something, all you really need is four boot kits, Molly grease, 12 new bolts and washers, and one good used 108 mm end cap.

The docs had me most of the afternoon so I am still a little goofy. I’ll look up part numbers in the morning.

The good news of the day is I found another stash of Porsche Factory “Service Information Technik” booklets. My goal is to find copies of every one that was printed. I’m getting close.

Best,
Grady

[rcecale]

Hey, Grady! Hope you're feelin better real soon! The doc's can really put a whammy on ya in the name of making ya better! I really appreciate your chiming in here. Now more than ever.

I'll talk with Pelican in the morning and get some part numbers and prices so I can make a comparison between the axles. I have some windows I need to install in our breakfast room tomorrow and then a wedding tomorrow evening, so I won't be able to do much work on this until Sunday...the lawn can wait.

Once I get the axles out, I'll be able to make a better determnation as to what I need. Uh....actually, how 'bout I post some pics and you guys can make that determination for me. If I can get away with just the boot kits, that would be great! I'll just stick with the list I posted earlier....kits, bolts, schnorrs and moon clips. Gonna have to change my order anyway, so I'll cancel the one I've got and re-order once I've got a better assessment.

Thanks again, Grady! Be well!

Randy

[randywebb]

Is this what you need re axle nut?

http://www.pelicanparts.com/catalog/shopcart/911M/POR_911M_suspen_pg12.htm#item47

A-332-806-00

[rcecale]

Looks like the nut I'll have to remove to get the axles off. Thanks Randy! According to that article in the link I found, it should be a 32mm. I believe I have one of those from when I tore apart my tranny last year.

Thanks!!!

Randy

[Grady Clay]

Randy,

Confirm a few things for me:

1) What is the Type Number of your transmission? 915/72 or 915/73?

2) Was there was an end cap on the inboard CV joint that didn’t come loose?

3) Was there no gasket between the CV joint and the transmission flange? Is it a flat surface without a step for the gasket?

4) What is the length of the “cheese head” bolt (socket head cap screw)? That dimension is measured from under the head of the bolt to the end of the threaded end.

5) Does the bolt diameter measures nominal 10 mm?



Your situation illustrates how careful you must be to get the right set of pieces. There is a mid-year change in ’86. The early version (G15.69/70) has a CV gasket but no end cap. The later version (G15.72/73) has an end cap but no gasket.

I think I have you the right illustrations and part numbers posting soon – the best I can.

Best,
Grady