1996 850T CV boot replacement--stuck on circlip

rocketman4321 · Post by **rocketman4321** » 12 Sep 2015, 16:18

I'm replacing the passenger's side CV boot. Axle's out, joint cleaned and repacked, boot on the shaft. But I can't get the circlip in the GKN kit to work for the life of me. It's seems small--tends to fall out of the groove in the joint assembly, so I tried putting in on the shaft first--no joy. I can't get the thing open onto the shaft for the life of me. My old clip seemed larger, but was broken. Is this the right part?

Also, kit had one packet of grease. Is that enough? It did a pretty good job on the bearings, but not much to pack in the housing.

Post by **cn90** » 12 Sep 2015, 16:47

Been there done that, the GKN kit has the wrong circlip.
Just re-use the stock circlip.

Post by **erikv11** » 12 Sep 2015, 17:07

Do you still have the parts of the broken circlip, to measure it? I don't have one or I would measure it for you.

On the grease: one packet should be enough, how many grams did it say was in the packet?

Post by **misha** » 12 Sep 2015, 18:10

I always re-use the old one.
You don't have other choice but to make your current circlip to spread a little more,since your old one is broken.
Gkn kit is oem kit for these cars.I don't know how the circlip can be wrong.

Post by **cn90** » 13 Sep 2015, 09:46

misha wrote:...Gkn kit is oem kit for these cars.I don't know how the circlip can be wrong.

Because GKN packs the wrong clip from factory.

I wrote my experience in the DIY CV Boot:
http://www.bimmerfest.com/forums/attach ... 1442158270

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- The GKN Boot kit contains: Boot, new 36-mm Nut, clamps and the circlip. The problem is: the new circlip is WRONG size (it took me 1/2 hour to figure out that it was wrong size)! I simply re-use the old circlip.

rocketman4321 · Post by **rocketman4321** » 13 Sep 2015, 10:23

That may be so. The box says #300427 Volvo, which appears to be the correct kit. However, in addition to the circlip, the boot was a bear to get on the outer joint (large end) and the large clamp seemed at least 1/2" too small. I've done at least a half-dozen CV joints (usually with GKN), and this is by far the worst.
Anyway, I reused the broken circlip--seems to just be the "ear" broken off, and it engaged the groove. 80 g of grease--1 packet. And I had to salvage the original large clamp. The small one worked, but had to be taken in a notch or two before crimping.

Thanks to all for the help!

Post by **cn90** » 13 Sep 2015, 10:41

Don't worry about it.

The circlip sole function is to seat the CV joint at proper depth.
Even without the circlip (which is not "kosher"), the car will run fine because once the CV joint is seated to the correct depth and installed in the car, everything is fine because what keeps the CV joint in place is the press fit (when you hammer it in). It is very very tight even without the circlip.

Chances are you will never deal with this circlip again, the car is now some 20y old...

rocketman4321 · Post by **rocketman4321** » 13 Sep 2015, 15:59

Yes! Exactly my thinking...whoever has to dig that circlip out may have a bad day! Not pretty, but in, done, working. And much quieter with the new wheel bearing that was the real purpose of the job. Noticed the boot cracking while I was checking the wheel bearing. Old one was definitely rough.