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| Here's how your CV should look on the axle
(less grease).
With the axle removed, pack the grease with a
grease needle attachment for your
grease-gun. To clean up an existing CV it's nice to
have a solvent tank. But if you don't have one of those, use a roll of
paper towel and be patient, go slow, and read all of these tips below BEFORE
you start the job. |
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| Make sure the CV will slip onto your axle
splines easily. DO NOT use a hammer to tap it on. If the CV
doesn't slip over the spline easy, look at the axle end with a magnifying
glass to check for spline damage. Sometimes the splines can be
mushroomed on the end. If they are damaged, sometimes a fine file with
a 90 degree edge can clean up any damage to the end.
Hint: This picture shows an axle with a flat end, which is old
school. The new style axles have a dome on the end to prevent the
mushrooming of the splines. If you're buying new axles, insist on the
dome type, they work better. This axle shows signs of mushrooming,
which requires tedious filing of each of the splines with a triangle file.
It's not fun, but it needs to be done. As the axle ages the filing job
becomes easier each time you service the CVs because there's less metal to
file. It eventually turns into a quasi domed axle....kinda sorta. |
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| A key trick to assembling your CV
is to insure the orientation of the inner star gear and the outer case is
correctly aligned. It's not difficult if you know the secret.
When you start installing the ball bearings you simply have
to line up the WIDE walls of the inner "star gear" with the NARROW walls of the
"outer case",
and vice versa, as shown with read lines in this picture. If you do this right the
CV will swivel around like it needs to for long travel suspensions. If
you do it wrong the CV will have almost NO MOVEMENT to pivot freely.
You'll immediately know something is wrong because you'll struggle bolting
up the CV's to the trans flange and hub assemblies. There's a 50%
chance you can do this wrong if you're not aware of this assembly trick. |
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| CV Clocking In some applications
where 930 CV's are stretched to the limits of their angle range you may
need to "clock" the two CV's with each other, perfectly on the splines.
Many cars that do not stretch the limits of a 930 CV past their
recommended 26 degree range and may not need CV clocking to work right,
but it's a good idea to clock them anyway, regardless of your max angle.
If you've never clocked your CV's and you've never had a problem,
that's because your car is designed within the 930 CV range limits,
which is a good thing.
Clocking the CV's doesn't take much effort, it only takes
the knowledge of how to clock them and the effort to remember to clock
them when you're reassembling your axles during your annual CV service. So this is a good
thing to practice.
Annual service? Yes, if you want to maximize the
life of your CV's you should remove and inspect the CV races annually.
Checking the ball bearings for wear, along with inner and outer
bearing races if the inner star gear and outer case on an annual basis
is proper maintenance.... or every 15 trips to the dunes. This will
minimize the risk of breakdown during your valuable duning time.
It will also minimize the risk of ruining an axle caused from a broken
star gear. Annual maintenance will reveal abnormal wear before
it's serious enough to break and mess up the axle splines.
To clock your CV's you must understand this simple
rule of thumb, Wide aligns with Narrow. In this
picture look at the outer case bolt holes. Each hole has a
corresponding race wall width, or "gear width" as some folks call it.
3 of the holes have a WIDE width, the other 3 have a NARROW width.
To align them properly look at the inside of each CV installed on the
axle, viewed from the center of the axle. The objective is
to align a WIDE race wall on one CV
with a NARROW race wall on the other CV. "Wide aligns with
Narrow", as shown in these pictures.
In addition to "eye-balling" the alignment, to insure alignment
of the CV's on
the splines, you could also buy a 3/8" steel rod the length of your axle and insert it
into one CV hole of each CVs after you think things are aligned. These
holes are exactly 3/8" ID. When the rod is installed there will be no
question about alignment if the rod easily fits through and the CV are
square with the axle, assuming the N and W holes are aligned as illustrated.
When the rod is installed, both CVs must be square with the axle,
perpendicular. If they aren't, you're likely not aligned, possibly off
by one spline. |
These two pictures (above and below) depict the
right axle assembly. The left side would look the same.
N aligns with W below as shown with arrows.
Both CV's are the same so it doesn't matter which one goes to the
transaxle, but it does matter which side you reinstall a used axle.
Always install the axles on the same side as it was originally installed
to keep the twist pattern of the axle the same. |
| Axle Orientation
When servicing your CVs it's very important to install
your axles on the same side as they were previously used when
reassembling. So before you start yanking out the CV bolts, use a
felt marker and mark each axle:
RIGHT and LEFT Comprendo?
If you orient the axles identical to how they were
removed this will insure the twist pattern of the axles will be in the
same direction as they were originally "broken in". If
you fail to install them on the correct side, and reverse
the twist pattern of the axle, this can weaken it, possibly inducing failure.
And if you don't think axles twist, take a look at the chipped powder
coat of this axle near the splines in these pictures. Yes, they
twist, and they set a "twist pattern" from the first day of use.
Some folks are also anal about keeping the axle
orientation on each side the same, which isn't a bad idea. The if
you have the right side axle on the right side, flipping it doesn't
reverse the twist. But some folks believe the twist may be
different since power is delivered from the transaxle side.
Whether or not axle orientation on one side makes a difference is good
to discuss around the campfire at 1am. :-)
Don't forget to label the axle side BEFORE disassembly. The felt
markings can be removed later with lacquer thinner, or simply mark them
in the area UNDER the CV boot so it won't show when reassembled.
DO NOT mark the axles with an engraving tool !!
BAD idea. |
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