Well now that I've taken some time to study these little beauties I am very, very impressed with the design!
However, I am wondering if I screwed up - I did not note which direction the hub/inner race faced in relation to the outer ring when they came apart - two just sort of came apart and I wasn't quick enough to note the relation. Am I dead in the water if I put these together "backwards" so that the hub does not face the direction the ring faced when I took them apart? I guess I am hoping I find the hub chamfer and can set that to face the same direction as the outer ring's identification ring.
Another quick question: Should I zip tie the boot's small end? I do understand there are bumps on the axleshaft to handle this, but I want to be very sure nothing will happen.
One thing to note: The instructions in the link
http://www.type2.com/bartnik/cvjoints.htm mention that the line on the outer ring should be closest to the boot - this is not the case: the line should face what will be the wheelside or the transside. The thicker section of the outer ring (delineated by the line) should always face one another, towards the axle center.
Note also some mention that the concave washer should be omitted. I don't believe that is the case.
My question, about the balls falling out, has to do with the fact that a new joint should not be disassembled because the tolerances are so close you will never reconstruct the CV's hub, inner race, and outer ring. Wow!
Finally, the instructions that Warren provided in that link are great. How often do you have a manual that asks "Please, remember not to..."
John