CV housing bent by axel, replace or re-form?

[rollandburn]

Hi, during a suspension rebuild on my '85 911 I noticed the CV housing on one of my axels is bent pretty good. My options are...

1. replace whole axel $$$$$
2. replace damaged parts $$$
3. diy hammer the metal back into shape

I had no indications via driving feedback that anything was wrong which is why instead of buying a whole new axel or buying parts I'm considering the hammer. I suspect the damage was a result of the axel being physically reefed on during a bearing replacement done at EU Autowerks because there is no impact damage on any of the parts, the boot was fine, and when rotated the axel it fits perfectly into the triangular area of the stretched metal. Also, I had the engine out years ago and didn't notice this damage.

Assuming there isn't significant CV wear upon inspection, what I don't know is if that bent housing does anything to keep the CV in place, and therefore should be replaced because it needs to be perfect... or if I can hammer it back into 'close enough' shape and keep using? I will say that when i rotate the axel shaft by hand and let it follow the contours of the bent metal it does indeed 'lock up', requiring me to bring the axel back towards the center to relieve the locking. 1. I can't see the axel ever naturally moving through that far-out range while on the car, and 2. the original shape of the housing wouldn't let the axel move that far anyway which means that 'locking' wouldn't happen.

Like I say, the boot was fine, no leaking or tears etc... in fact I almost didn't even notice the deformation with the boot on, once I took it off it was pretty obvious. Take a look at the pics and let me know what you think. Cheers.

[911 Rod]

I wouldn't be messing with this thing.
Too bad, I just sold my old ones for $100.

[Nine9six]

The thing about it, is the boot flange housings are not sold separately.

The housing serves to captivate the CV joint grease and attachment point for the large end of the boot; it is not structual for the CV joint, and can indeed be used as is; just as long as the integrity of keeping grease in and debris out is maintained.

[theiceman]

Did you talk to Coutney ? Its always good to revisit a shop or have a discussion with them before publically shaming them like this .

could you not rig something up and essentially " pull it " ?

[Discseven]

If the "relationship" between that cap and bearing housing can take some force... I'd bend that cap back into shape.If it looks like more damage may come from a bend-back, would think some more.

[rollandburn]

Public shaming? Ugh. The point was a qualified mechanic was in there last. Yes it will have to be pulled out from the inside somehow if that's the route I go... just wasn't sure if the shape of that piece had any effect on the mechanicals. Nine6six indicated this piece is not structural for the joint so I'll do the clean, inspect this weekend and reform if everything's good with the innards.

[Josh D]

It's part of the boot assembly. Just replace the boot, they're cheap. As is, the boot will eventually tear.

[Nine9six]

Originally Posted by rollandburn

Public shaming? Ugh. The point was a qualified mechanic was in there last. Yes it will have to be pulled out from the inside somehow if that's the route I go... just wasn't sure if the shape of that piece had any effect on the mechanicals. Nine6six indicated this piece is not structural for the joint so I'll do the clean, inspect this weekend and reform if everything's good with the innards.

I am speaking from experience here. Any squeezing or trying to reform the boot flange, will only make a bigger mess of things. This is currently only a cosmetic issue and one thats not visible, at that. I seriously suggest you leave it alone.

Your AXLE will never be at the extremes to rub the boot flange, unless the cap screws holding the inner cv to the transmission, back out. At this point, that silly little boot flange will be the least of your worries, once the axle and inner cv joint litterally beat the snot outta the underside of your car and surrounding components!

(Axel: a jump with a forward takeoff from the forward outside edge of one skate to the backward outside edge of the other, with one and a half turns in the air.)


The deformation is from removing the suspension and allowing the weight of the whole hub and wheel assembly to rest on the flimsy by comparison; die formed, sheet metal boot flange.

Not to digress, but are your cv joints making noise (clicking). If the boot is not torn, which its not and there is no indication of cv failure; I'd clean things up repack and put it back together.

If you're worried about cv wear, you can swap right and left axles, and realize extended life of the cv joint.

Search for Pelican member name, "Grady Clay" (RIP) posts, for all things CV joint related. Porsche guru extraodinaire.

I miss you, Grady!

[Porboynz]

I have seen similar deformation on lowered suspension setups on earlier cars, to me it looks too regular in shape to be from letting the axle assembly drop free from the suspension. A big pair of channel locks and some gentle persuasion might get it more circular, but as long as the boot seals it will probably be fine. Of course if the CV is toast replace it, a liberated driveshaft is an ugly thing at any speed.