CV joint repacking/cleaning questions

Hi,

I am hearing some clunking noises from the rear of the car. It's not the rear sway bar bracket since they are both in good condition. I thought I might try to clean the cv joints and repack them. Are there any tricks to doing it? What's the best way to clean them and also the best way to insure that I packed enough grease in them? I read Warren Hall's response to Cv boot replacement but just wanted a little more info.

BTW, I have changed a boot before, but I didn't bother messing with the joint itself.

Thanks,
Neil Kumpers
'73 911S targa

As far as instructions for cleaning, inspecting, and repacking go, until you have gone through it yourself, the best source of info is those Bentley VW manuals! As far as diagnosis of the clunk goes, once you get the CV-joint loose from the transaxle, and free to move around a bit, if it is very stiff and viscous to move around, it is probably not the source of the clunk. If, on the other hand, the loose end is very 'floppy' and the axle moves very easily around in the secure CV-joint at the wheel-end, then you have, most likely found CV-joints in need of repacking or replacement. The replacement decision is entirely dependent upon the condition of the 'grooved' races for the ball bearings inside the joint. Heavy wear and pitting or a 'burr' raised on the race is a clear indication of a non-usable joint for the long term, though it could be put back on the car for a short term until a new one can be obtained.

As far as the quantity of grease to be applied to a repacked joint, you want an excess amount built up on both sides of the re-assembled 'bisquit' before going back on the axle, probably a large mound of 1/4" to 3/8" on both sides, but you don't want the boot filled, or overflowing, or bulging! You also don't want any air gaps in the joint, either ... filled completely up with Moly grease is how the joint needs to be when the axle goes back on the car! I hope this helps, as this really is the messiest job you will ever see! And, it is not one you see much written about, with the 'swap-out' mentality being the prevailing philosophy of maintaining vehicles these days! One final word, while you have the car up on jack stands, it is a good time to remove, clean, and lubricate your starter!

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Warren Hall
1973 911S Targa