Ok, so I had a boot blowout on the R53, so I got the Empi CV boot replacement kit from PelicanParts to change the boot. So I took out the shaft, cleaned the joint packed the grease and reinstalled.

For anyone who has not replaced the CV joint with the Empi kit it comes with the boot, 2 large CV clamp rings, 2 small CV clamp rings, and 2 bags of grease.

Going to work today I noticed a knocking sound coming from where the CV joint is. Now, when I installed the boot I used only one bag of grease, because I thought that it gave you enough for two boots for some reason since it had 4 clamps and 2 grease bags. But looking at all the pictures I see of the kit online it shows only 2 clamps, 1 large and 1 small.
SO.
Could the knock be caused by not enough grease in the joint? Anyone with experience with the Empi kit or similar that could give more information? The instructions did not refer to two bags of grease being used.

 

Usually...if you wait till a CV boot tears....sand/grime gets in...and the joint will fail pretty fast...even if re-booted..
The boot replacement kits are best used in cases where you see the boot is cracking..but not failed....
Not sure about your knock...but if it is failing..it will rapidly worsen....

 

Upon further inspection and hearing, I have concurred that it cannot be the CV axle. Because 1, there is no wear on it whatsoever. Cleaning everything off, everything is shiny. and 2, it is not a consistent knocking/clicking or anything, and does not happen around corners where it would be binding. It is more of a hollow knocking sound that only happens over bumps or dips.
I must have knocked something loose when doing maintenance.

 

You might want to look at your bushing at the rear of the lower control arm...mine just wore out on the passenger side so I ordered the parts and am just waiting for time to put them in...

 

I am in need of the same advice as MiniMerkel for the Empi kit as far as how much grease to use. I too ordered from PelicanParts and got the 2 bags of grease and 4 clamps. I really need to know before going further if I am to use one or two bags of grease. The simple directions with the kit only mention one bag, but I need to be sure.

 

I believe you only need to use one bag of grease since it gives you enough clamps for two boots it would only make sense to have enough grease for two boots as well.
I used one bag and haven't had any problems. i.e. the boot is still on, no clicking, knocking, etc.

 

Thanks for the quick response. I called PelicanParts as well and their response was "Just fill up the joint. If 2 bags does it then good, if too much then just use one bag." That's about the lamest automotive repair advice I've ever been given. I'm going to stick with one bag per your advice so there's no overfilling issues.

 

Another question: is it ok to reuse the circlips when reinstalling the tripod bearings? The Empi kit comes with some rounded metal clips that are a bit too loose for my liking.