CV Joints on Mk3.1 Complete Kit IRS

[EngineOil]

Hoping for some guidance here. After 1500 miles, I began to get a clunk in the rear end when changing torque (either after shifting from 1st to Rev or when clutching). Now at 1600 miles it has worsened.

I got under the car and found that I can reproduce the sound by taking out slack in the inner CV joints which appear to have a lot of play. I can spin the driveshaft through about 1" of circumference while taking up the slack and then hearing the clunk in the inner CVs.

I am trying to convince myself that its the CVs and not the differential as I can feel the rotation through the outer wall of the CV when the driveshaft is spun through the slack.

I would like any thoughts you might have as the car has not been driven hard to date. In addition to what you think might be occurring, can you tell me if pulling the half shafts involves getting into the differential to release the c-clips or whether that can be done from the ears.? Thanks in advance.......

Jamie

[Bob Cowan]

Removing the axles is pretty easy. Just use a large screwdriver and pop them out. You don't need to open the diff.

I'm using some heavy duty axles from Disc-Brakes-R-Us. They've been there for a few years without any sign of wear. And I beat on them pretty hard.

[michael everson]

Thats not normal. There should be very little play if any in the cv joints while rotating. Sounds like something is worn out I would jack up that side of the car and rotate the wheel and see if you can confirm that the play is in the joint itself.
Mike

[EngineOil]

Bob, thanks for the screwdriver trick. And, thank goodness I don't have to open the diff. Will I unbolt all of the knuckle bolts and take the entire assembly off.....or do I start with the axle nut?

Mike, I did a lot of checking with the car jacked up. I am convinced the play is in the CV joints (its either that or the diff, but I can hear the CV move inside the outer wall when I rotate the driveshaft). Seems like its more one side than the other. But why so early (1500 miles)??? I will add that the side I am most concerned with was the side that seemed like the c-clip was not locking well into the diff's spider gear. Do you think that taking apart the CV will show obvious signs of wear if that's where the problem is? If you happen to know how I can refer to the C-clip (part # or axle reference) to get a new one, please let me know.

Thanks for your help.

[Bob Cowan]

I find the easiest method is to remove the three knuckle bolts, pry the axle out of the diff, and remove it all as one assembly. From there you can inspect the axle joints, replace the boots, etc.

[EngineOil]

Thanks again Bob
Jamie