Volvo 850 Outer CV joint interchange data

[cn90]

I need help from northerlights or any CV boot guru.

1998 S70 GLT with 180K miles.
Last rebooted at 90K, it is now at 180K, Left OUTER CV boot just cracked, spilling grease.

I already have the GKN 300439 at home but I need to buy an INNER Boot.
Just got under the car and measured the metal shaft: ID = 24 mm, OD = 92 mm for both INNER and OUTER CV Joints.

My question is for INNER Boot. Per northerlights, he used GKN 300597 (ID 21mm, OD 82 mm)!

See the photo I just sketched to show how northerlights did it, I wonder how you can expand a boot with 82mm into a ring with 92 mm?

PS: Volvo still sells INNER boot for Turbo axle, PN 31256230, about $34 or so.

CVBoot.JPG (55.87 KiB) Viewed 3728 times

[cn90]

UPDATE:

I decided to be the guinea pig re GKN OUTER for INNER side. It was a no go!
I ordered another GKN 300439 to test if it fits the INNER side:
- It is a bit loose (slightly bigger O.D.) but that is not the problem.
- The problem is in the "lip" profile (cross section profile), it does not fit very well b/c of the lip profile.
- So maybe nothernlights' idea of using Audi INNER boot for Turbo INNER side was OK (he said it was a tight fit).

I am glad I didn't cut the factory inner boot. I saved it and re-used it, it was still in decent shape.
However, your best bet is to ask nothernlights re Audi boot or better yet, cough up $35 and get the Volvo Inner boot from dealer.
Since this is the inner side and not subject to constant flexing/bending as seen in the OUTER joint, you may be OK with EMPI INNER (sold as INNER for $12) or Rein boot (sold as a pair for $22). But given how much work is involved, I'd vote for Volvo OEM boot: the price difference is not that much.

98-Volvo-Axle-02.JPG (37.38 KiB) Viewed 3669 times

A NOTE on Trans seal:
- Note that it is about flushed or at most 0.5mm from surface. Don't drive new seal in too far, you may end up with a leak.
- The seal has 2 lips: the inner lip is the actual seal (it is tightly sealed due to the garter spring), the outer lip is basically there to prevent dirt from coming in.
- I used the pry bar to remove old seal.
- New seal: although you can use a 1.5-inch PVC coupler, I prefer a small piece of wood and install it flushed.
- Seal is by Corteco (Freudenberg-NOK mfg), purchased from rmeuropean dot com for $11. It is an exact fit and finish.

[sleddriver]

Excellent write-up CN! Great photos, diagrams and labels!

I have new Corteco axle seals for next time I do this, though mine don't leak, are now 19yrs old wtih 215,425mi.

Q on replacing inner boot on pass. side. How to install it when the inner joint won't come apart/slide apart? Trying to slide it over the other end means dealing with the large dia. bearing. My axles are not OEM. Indy bought them from WorldPac long time ago.

[cn90]

sleddriver,

Re Pass Side axle.
The bearing sits INWARD of the inner CV joint.
So you have no problem working on either Inner or Outer joints.
I am posting a photo from my other DIY so you can see:

[sleddriver]

Excellent point! I stand corrected...and obviously confused! I'm going to have to redo the outer pass boot due to a rip after only a year or so. I had such difficulty just removing the outer joint (first time, wrong tool), I may have just been finally relieved to get 'er done, that I forgot about doing the inner boot BEFORE the outer!

Thanks for the clarification!

[mecheng]

Cn90, OD for inner on my cv joint was not 92mm, therefore the Audi boot fit perfectly. You can see the pics in the earlier part of thread, the rein kit has different sized boots.

I've had to replace two inner original GKN boots so they do eventually wear, your job is done but something to think about next time. I would have put on an outer boot on the inner in your case.

[erikv11]

I've also done one or more inner turbo boots, have only used the Audi part, it fits.

[cn90]

A little bit of history on my 98 S70 GLT with 180K:

1- (R) side: dealer installed a NA axle years ago. I know for fact the OUTER joint OD is 82mm b/c I installed the boot recently.
I also installed the INNER using Audi boot (82-mm type), which fit perfectly as described in the 1st page of this thread.

2- (L) side: this is original for sure, b/c the INNER boot said "made in Germany". I know the dealer rebooted the (L) side at 100K or so (I have records).
The OUTER joint OD is definitely 92mm. I remember reading somewhere (maybe I am wrong) that the inner boot for turbo (Volvo OEM PN 31256230) is larger than NA Axle INNER OD, thus this experiment. When I had the INNER joint apart, the diameter was certainly more than 82mm, it was about 92mm or so.

I just checked Volvo OEM PN 31256230, which has the dimension of: L = 85mm, ID = 24mm, OD = 92 mm.

So, northernlights managed to stretch an Audi 82-mm rubber boot over a 92-mm joint, interesting!

PS: As I mentioned above, if I have to do this again, I would buy Volvo Inner boot for $32.

[cn90]

OK,

I am back with an ATF leak, I drove the seal in 3 mm too deep!
There was a post in volvospeed many years ago, someone had the same experience (installed the seal too deep = leak).
I read it years ago but forgot!

Anyway, I am getting good at removing axle LOL...

1. See the seal is 3 mm too deep:

2. NOTE the "Main Seal" area (where the garter spring is) and the "Wiper Seal" (aka "Auxiliary Lip").
Once the seal is 3 mm too deep, what happens is when you insert the axle, the Main Seal is pushed further inward and sits at the beveled edge instead of the Main Shaft area:

3. Even with new seal, one side was a bit 2mm inward. I was mad at myself but no worry, I improvised!
The solution is a pair of right angle-pliers!
Try it out so you know how deep to insert WITHOUT damaging the Main Seal.
Then insert the pair of right angle-pliers and gently pull the seal out.
PS: Per another thread in volvospeed, I use a thin layer of black RTV on the outer edge (where the seal meets the housing) just to be sure.
Well, I don't want to do this job again any time soon.

Anyway, so far so good, no more leak...

[sleddriver]

Good info. I have a pair of these seals to go in next time I pull the axles. Both Corteco. Current seals are OK and don't leak.