Date:         Mon, 12 Jan 2004 17:02:51 -0800
Reply-To:     rcampbell-vanagon6706@MAILBLOCKS.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Robert Campbell <rcampbell-vanagon6706@MAILBLOCKS.COM>
Subject:      Re: Noisy CV's below Zero degrees F?
In-Reply-To:  <rcampbell-017XeAG8YcWIK14i+n9Jx1/6k4yC1Er@mailblocks.com>
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-----Original Message-----
From: rcampbell-vanagon6706@mailblocks.com
To: maxjoyce@IPA.NET
Sent: Mon, 12 Jan 2004 14:19:03 -0800
Subject: Re: Noisy CV's below Zero degrees F?


Max,
I just changed my CV's this past weekend (BTDT now).  There was no rot or any sign of anything wrong with them other than the knocking noise coming from back there that was proportional to the speed I drove.  I would think that if you have any rot on the boots, with noise in that area (if it is in proportion to speed), then your CV is most likely done.  When I took my CV's off, they looked like they were in very good condition, however the grease was clumped up, indicating that quite possibly in the past 142,000 miles on my '91 Carat, they were never repacked.
One concern:  You stated it is making a "strange metal sound", my failed CV clear made a "knock" or "clacking" noise that was in proportion to the speed I drove, the faster I drove the faster the noise, at stop, nothing.  It could be that you have a more severely failed CV joint that is chewed up now, but with rot taking place something is definitely amiss.
So, I guess my point is, you may or may not see seepage depending on the state of that grease (my stuff was mostly clumpy, so I don't think it would have seeped out if there was a hole, and even good grease may move slowly when really cold).  One thing I can tell you is that the job isn't difficult (at least, mine wasn't).  Also, I'd recommend that you contact Jeff at www.vanagonparts.com, he has the CV's with boot and grease for ~$43.00 I think, www.busdepot.com is $54.95 -- add shipping to your area for each (I do business with both).  I spent about 3 hours per side, cleaning everything up along the way, making absolutely sure that nothing foreign got introduced to the new boots, CV's or the areas where they bolt up (clean the old grease out of there -- that's a must).  I was pleasantly surprised -- now, the good news for me is that I live in Florida, so working on the Van, in shorts, in January, is no problem -- although it was down below 70-degrees by the time we finished :-).  One note or variation to the instructions you will find out there:  when packing the grease in (wear some latex gloves, that grease can be a real mess), pack about half of it (1.5 oz.), or a bit more, until it oozes through to the other side, that was you KNOW its all over the inside.  Then pack the other side, put the remainder in the boot and I left just a bit over to put on the wheel/tranny sides (the non-boot side).  I'm now tooling around until I hit about 400 miles, then I'll re-torque the bolts to 33 ft. lbs. (check them to confirm they are holding).
    -Robert
     '91 Carat, AT, 142K
-----Original Message-----
From: Max Wellhouse <maxjoyce@IPA.NET>
To: vanagon@GERRY.VANAGON.COM
Sent: Mon, 12 Jan 2004 14:18:37 -0600
Subject: Noisy CV's below Zero degrees F?

My 90 GL was making a strange metal sound the last week or so. when
starting it up and driving off to work near or below zero, I heard this
sound which seemed to come from the driver's side rear axle. it was noisy
the better part of the 3 mile drive to work. When it was 20 degrees that
afternoon, driving home I heard nothing. Initially I thought it was the
wind flapping my loose fiberglass panel against the body, but it also
happened the next day identical circumstances. Now that it's above 32
degrees F, there's no noise. Taking advantage of the warmer temps, I
crawled under there only to find some rotting of the inboard axle boot but
no seepage of CV grease. Had slightly worse rot on the passenger side
inboard boot and some signs of seepage. The CV joints have some miles on
them and re packing was in the plan for April, but what gives? Could water
have migrated to the inner workings and frozen to the point it was
preventing grease from getting to the metal? I am not an experienced
vanagon driver in real cold weather, so help for the Northern newbie would
be a big plus.

TIA

Max