98 V70 CV axle inner and outer boot replace - question

[98v70dad]

I've collected all my parts and spent the evening reading many of the threads about replacing boots. Tomorrow I'm going to dive in and finally put on my new boots.

I have a nice junkyard turbo axle to install in my non turbo car. There are no cracks in the boots but I want to replace them since they are pretty old. I bought GKN boots per recommendations on this site. One of them is for an Audi (inner side) ....anyhow I'm certain I've got the recommended boots, although the inner one looks small to me.

My plan is to remove the OUTER end (from what I've read this isn't that difficult), clean out the grease with rags (I don't expect to find any grit or dirt in the joint) and pack new grease down the central splined hole. This should be pretty easy to do with the right sized dowel (or socket with end taped) to push the grease in since the shaft will be removed. Remaining grease will be slathered on top of the race and cage and then into the boot. Of course if there is any grit in the joint I'll have to disassemble it completely, clean it, reassemble, etc - a lot more work.

This leads to my question - With the shaft still installed on the INNER end how do I pack grease into that end? It seems that all you can do is to try to push grease into the bearings with your fingers which I cant imagine is very effective. Any tips or tricks for doing this? I've spent the entire evening reading various threads and didn't see this subject covered (maybe I overlooked it).

NOTE: For those giving me advise to get me to this point, I decided not to worry about the carrier bearing for three reasons a) its too expensive to replace and too much trouble to try to grease it b) its a sealed bearing intended to go the distance while being exposed to the elements. Its last 10 years on a shelf at a salvage place was easy duty compared to life on the road. c) the carrier bearing seemed fine when I inspected it.

[cn90]

To grease the INNER CV Joint, undo the Oetiker clamp (the larger clamp), then lift the rubber boot and shove some grease in there.
If you are careful, then you can re-use the clamp. Better to use new clamp though.

[98v70dad]

To grease the INNER CV Joint, undo the Oetiker clamp (the larger clamp), then lift the rubber boot and shove some grease in there.
If you are careful, then you can re-use the clamp. Better to use new clamp though.

I'm replacing both boots and planned to wipe the old grease out of both inner and outer. Does just shoving new grease into the assembled inner joint do the trick?

[cn90]

Yes,
- For INNER, just wipe off old grease as much as you can (push the joint inward to expel the old grease outward).
- Then with the joint pushed all the way in, pack new grease ---> boot ---> then clamps.

[98v70dad]

Yes,
- For INNER, just wipe off old grease as much as you can (push the joint inward to expel the old grease outward).
- Then with the joint pushed all the way in, pack new grease ---> boot ---> then clamps.

Got it! Thanks.

[98v70dad]

Yes,
- For INNER, just wipe off old grease as much as you can (push the joint inward to expel the old grease outward).
- Then with the joint pushed all the way in, pack new grease ---> boot ---> then clamps.

After a little bit of effort I got the outer one off and I felt that it was worth cleaning out the old grease. Took it apart, cleaned it up and found that the hardened surface is spalling at the edge of the bearing race in the big casting. 2 of the 6 races are like this. One is the size of a pin head (really small) and one is 1/16 to 3/32 (bigger but still small) Is this worth continuing with? The part has no slop at all, but I would expect the spallied edges to to grow. That said, if I hadn't cleaned off the grease I wouldn't know about it.

[98v70dad]

So, I got the CV axle all disassembled and I cleaned out the grease, repacked it and put on the new boot on the inner side. There was water in the grease - it spilled out like brown mud when I took off the boot. I took the joint apart on the outer side joint because I could feel some grit in the grease. When I got the cup all cleaned out I noticed that It looks like the hard surface has spalled in two places. Very small, tiny area - same spot on two of the six bearing grooves. I'm going to go ahead and finish up although I'm not sure its a good idea to put this axle back in service with the water goo-poo grease on the inner side and the tiny spall area on the outer side. I got it all disassembled in about an hour and have spent the rest of the day trying to get the outer joint back together. I can get in 3 or 4 bearings and then there isn't adequate movement to get in the last 2. I'm so frustrated I'm going to clean up the CONSIDERABLE MESS and try another day.

Please someone give me some idea how to get that joint re-assembled. I found a link to a guy doing his Audi CV last night and thought it would be a good reference. Unfortunately I think our CV's are slightly different because what he was doing doesn't work on my car.

Also, any comments on whether or not the axle is worth saving would also be appreciated - I'm tired of working on it today and my brain has started encouraging me to go to NAPA and just buy one!

[sleddriver]

I wasn't able to remove the balls as he did.

[cn90]

The youtube below is from a Honda but it is virtually identical to the Volvo Outer CV Joint.
Make sure the orientation of the cage is correct.

[98v70dad]

The youtube below is from a Honda but it is virtually identical to the Volvo Outer CV Joint.
Make sure the orientation of the cage is correct.

C

I had no problem at all getting it apart. It's putting it back together that is my issue.