Michael,
To disassemble the outboard CV joint of a welded assembly; tap off the tin cover (it may have some sealant and is pressed on), tip the axle shaft until you can remove a ball bearing, repeat for the others and then the inner race (still attached to the axle shaft) and the cage will come out.
Reassemble mostly dry in reverse order. I would put the partial assembly (stub axle with outer race, balls, cage and axle shaft) in the freezer to get very cold. I would heat the tin cover with some sealant in place to around 100C and quickly install it over the cold CV joint and clamp it in place with C-clamps, vice, etc. Once things have set for a while, grease the CV joint. I use a small hand “grease gun” that has a ~3 mm plastic hose. The hose fits between the cage and races so you can get grease inside. Articulating the CV joint will spread the grease. Next install the new boot and clamps.
Now you are ready to install the inboard CV joint; clamps first, then boot, then tin and finally the CV joint (and end cap if used). I grease the completely assembled CV joint from the end cap end. Use the CV bolts and some nuts to get the tin covers clamped in place (with the bolt holes lined up!) right away and let set.
Jascha, I don’t recall seeing split boots like the swing axle VW and 356. If they are available please post a link. That would make an OK emergency solution. This won’t work for anything other than a slow-speed emergency fix. The split boots on a VW or 356 don’t rotate with the axle.
I don’t think this thread has the links to the other important threads.
Here they are.
Pelican
rcecale, Randy’s classic thread.
”Reconstructing Constant Velocity (CV) Joints”
“CV Joints”
http://forums.pelicanparts.com/showthread.php?threadid=62514
The following articles are a good reference for Lobro CV joints from Warren Hall:
http://volksweb.relitech.com/cvjoints.htm
http://www.type2.com/bartnik/cvjoints.htm
http://forums.pelicanparts.com/showthread.php?threadid=62514&highlight=joint+%2Aassembly
For those copying & pasting, here is the link to this thread.
”Carrera CV Boot Replacement“
Best,
Grady