Hey guys - hoping someone can shed some light on an issue I just created. Because that's how I roll.

I just replace my inner boot - and now? NOISE! WTF...wicked frustrated. It was totally quiet before - but after my last rallycross I was under the car and noticed the torn boot on the inner CV and the outer balljoint, too. New balljoint, new boot - now I'm getting a big clunking sound.

Pulled the axle again this morning and put a bunch more grease into the joint and made sure the clip was on the joint - no change. I've checked and rechecked - balljoint nut, axle nut, tie rod nut - just sounds like something is totally loose - not clacking like the joint is bad. And I can't seem to make the noise by pushing/pulling on the wheel - just when I'm driving - even the slightest bump makes it clunk.

Going to try putting the old balljoint back on - but jacking the car up and checking for play doesn't show any. Not sure what else to try - will buy a complete new axle next I guess...unless you guys have any thoughts. Just strange that everything was totally quiet before. And would a bad CV clunk? Thought just clack.

Thanks,

Pat

 

How about this question - should there by any space between the little 'collar' and the transmission case? Just got my new axle and the carrier bolts won't go in - it's off by about 1/8"...and I do have a little space between the collar and the case.

Now thinking this may be the problem I had with my old axle, although the carrier did line up perfectly on mine.

Fighting to try to get the axle in a little more - just doesn't seem to want to go. Really hate to think I need to put my old axle back in and take it somewhere.

 

Actually...according to the 'BMTroubleU' video my axle is in all the way.

So my only current issue is why the carrier on this new axle doesn't quite line up with the holes on the block. Probably my block is off...lol.

 

Aftermarket axel?

I'm. Betting the clip isn't allowing full engagement

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Yes, good question. Is it an OEM replacement or aftermarket axle?

 

Aftermarket. I was trying to find a rebuilt OEM but ended up with this EMPI thing from Parts Geek.

http://www.partsgeek.com/ss/?i=1&ssq=80-7911&x=0&y=0

Thinking I might try to swap the joint over to mine...or start disassembling the carrier and see how much trouble I can get in to.

 

This is a very common issue with any aftermarket axle. You might have better luck returning it and going back to an OEM replacement. Another option is to find a place near your location that does in house OEM rebuilt axles.

-Luccia

 

The clip...you mean that collar piece? This is how close it is...



Looks like it should go a little more - but it is as far as the stocker went (after I monkeyed with it, though), and looks the same as that video.

I started opening up the bolt holes in the carrier a little bit - I'm now able to grab the holes but would cross thread if I went in. Will do a little more. Hopefully it doesn't cause some other alignment issue.

OEM axles are worth more than my whole car at this point . Didn't know there might be local places to rebuild mine - good tip Pelican - will check around - thx!

 

Sir clip like in this pic. This clip has to fully engage for axel to seat correctly inside diff.



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Compare to other side ?

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This is the passenger side, so no clip. And can't compare side to side because how they mate to the transmission is different (or looks different because the joint is in the way on the drivers side so you can't quite see in there).

I wonder if there is something in the diff that's hanging it up - I struggled to get the axle out initially, now it seems to slide right in. Oh man...how much would that suck...

 

I had this problem. The clip would not go in. So I left it out. Thinking what is the worst that could happen. 1 year later the axle fell out of the car. Luckily I still had the clip. I remarked out the groove deeper and the clip went on this the axle clipped in. This was 3 years ago. All better now.

 

That's the drivers side, though - right? Or are you talking about a clip inside one of the CV boots?

According to the Mod Mini video and I also checked in the Bentley's manual there's no clip on the passenger side...true?

Thanks everyone for your responses. I appreciate it!

Pat

 

OP in ur first post u said this:

"joint and made sure the clip was on the joint - no change. I've checked and"

Maybe thats why the confusion

Take a pic of the axel u took out. Espically the end that is in the diff.

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Yes the clip is only on the drivers side.

 

Sorry, ya...didn't even say what side I was working on in my original post. But it's the passenger/right side. The clip I was talking about there was the one inside the inboard joint, that holds the knuckle on...had to remove it to get the new boot on.

Here's a pic of the diff ends:



And here are the axles side by side:


The inboard joints near the carriers are actually a little different - the casing of the original is dished around it whereas the new one is smooth...but not sure if they're different lengths. I'd love to disassemble both and get some really accurate measurements to see where the difference is.

Maybe once I wreck the carrier on the new one.

 

So, the sides of the carrier holes were getting a little thin and I still wasn't there - thought, hey, why don't I just my inner shaft with the carrier on it, and just stick it onto the new outer? Bazinga!

Spent the last hour disassembling both axles - had to remove the inner knuckles so I could swap boots since the casings are different. Didn't bother checking that their knuckle would fit into my casing since they looked that same.

See where this is going?



The new knuckle is just | | much too big...

Use my knuckle on their axle? Pretty soon I'll just be using my axle again. lol.

Man I don't want to spend $500 on a new axle for this stupid thing. Pelican, can I trust the aftermarket one you sell? Same EMPI brand as this one. Maybe I just got the wrong one...

 

GKN and Mini are very close in quality. They're also an OEM supplier. I would recommend going with the GKN, which is listed for $180 here. Just make sure to enter in your correct year and model in our parts catalog here. Click on Suspension & Steering > Axles, Bearings & Differential.

For Reference:


Let me know if you have any other questions.

-Luccia

 

I went through the same thing... Got the axle off Parts Geek. Big mistake.

My axle literally fell out when I was driving. Tore up a bunch of other stuff coming out.

Took it to a mechanic and he got one from NAPA. That one still didn't fit and I was leaking fluid from the gearbox.

They finally took that axle out, used a grinder to shave off a few thousandths of an inch. Finally clicked in and it's been good ever since.

Stay away from Parts Geek. And don't get one from Autopart International. It fit. But, wore out in a matter of months.

 

Oh yeah.... I spent like $800 total getting this repaired because of shitty parts.

If I didn't have AAA, it would've been worse.

 

Wow. What a mess. But I think you finally got to the end of it. You were chasing a ghost as the axle you got was wrong to begin with.

I would go with what pelican said and get the $180.00 one.

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Thanks for the info Luccia. I need the other side but see it on your site; good to know about 'GKN', will most likely go that route.

Not that I enjoy others misery, but glad to hear this isn't just something I'm doing wrong (because usually it is! ). Sounds like you got it bad, dcantwell - sucks!

Now quickly add me to your ignore lists, I'm going to move on to the supercharger oil replacement and pulley swap...

Thanks again everyone!

 

My pleasure and if you have any other questions please feel free to ask if you don't find any help in our DIY Tech Articles. Cheers!

-Luccia

 

Hate to bug you all again...but I managed to fab up some support for that axle around the carrier bolt holes and mount up the new axle. Same noise!

I must have put something together incorrectly, but not sure what. Sounds like the shock is loose or axle nut. Only checked those a thousand times.

I think the only thing that isn't new under there is the inner balljoint. Ugh.

Thanks

 

Are you able to give us a ring? I think speaking with a specialist over the phone might help you better than I can. 888.280.7799.