1.6L TD in a Dodge Caravan

[Black Smokin' Diesel]

Last night I finished installing the half shafts with the replaced CV. When I removed the CV, in the boot there was a spacer ring for the spline. I was guessing it was below the CV, but I could not get it to properly go there, so I put it on top. Anyone have experience with this?

I had this happen only when using new washers. I always end up reusing the old ones. With the CV on the shaft I couldn't get the circlip on even by hammering on with a flathead screwdriver (the circlip not the CV).

Where did you put the washer ? Next to the cir-clip, or on the other side of the CV joint?

I always put it between the shaft and CV. The circlip directly against the CV. The dished washer is there to prevent the CV from moving on the shaft. As long as everything it tight, you're ok.

[arb]

Last night I finished installing the half shafts with the replaced CV. When I removed the CV, in the boot there was a spacer ring for the spline. I was guessing it was below the CV, but I could not get it to properly go there, so I put it on top. Anyone have experience with this?

I had this happen only when using new washers. I always end up reusing the old ones. With the CV on the shaft I couldn't get the circlip on even by hammering on with a flathead screwdriver (the circlip not the CV).

Yeah, that's what I thought... since I was using slightly different years on the CV, it worked out that the washer under the circlip was tight, being a compression washer. I have one more spare. Hopefully I will not need it for years to come. This one gave warning of failure when the boot failed and I did not replace it right away.
Where did you put the washer ? Next to the cir-clip, or on the other side of the CV joint?

I always put it between the shaft and CV. The circlip directly against the CV. The dished washer is there to prevent the CV from moving on the shaft. As long as everything it tight, you're ok.

[theman53]

How is the van ARB?
And where have you been? Any updates

[arb]

How is the van ARB?
And where have you been? Any updates

Like you in Ohio, I've been freezing my parts off ;-)  The diesel is running strong. The inner (VW) CV joint I replaced a few months ago failed again just before Christmas. It appears I must have put the compression washer on the wrong side of the joint. Working for the Blue Oval, I was out of work for the Christmas break. It was too cold to fix, so I waited until Jan 2 to replace it with another used joint. This one I did a very good job of cleaning and repacking. Its boot looks better than before. I have driven it every day since then with no problems, other than no heat in the cabin. I think my Dodge heater controller requires more VAC than my old pump puts out, so the hot water valve never opens. We have a 3 day weekend tomorrow and its going to be above freezing, so I'll track that down. I have photos of the CV job, but have not posted them yet.

Otherwise, very happy with the 40 mpg I've been getting going 70 mph.

[arb]

I need to check my MPG as it appears its gotten better than 40 mpg. I calulated I should have had 3 gallons or so when I filled up for the first time this year - turns out it had 12 gallons in the tank ( I ran out on my way home the first week this year)

Here are the photos for the second CV replacement.

Broken CV
<a href="http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5610.jpg" target="_blank"><img src="http://i533.photobucket.com/albums/ee338/the_arb/th_100_5610.jpg" border="0" alt="Photobucket" ></a>

used donor CV
<a href="http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5611.jpg" target="_blank"><img src="http://i533.photobucket.com/albums/ee338/the_arb/th_100_5611.jpg" border="0" alt="Photobucket" ></a>

replaced back on shaft, this time with the compression washer on the shaft side of the CV. It is under conpression now. I had to use a drift pin and brass hammer to get the cir-clip on the end of the spline.
<a href="http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5612.jpg" target="_blank"><img src="http://i533.photobucket.com/albums/ee338/the_arb/th_100_5612.jpg" border="0" alt="Photobucket" ></a>

[NintendoKD]

WOW..... just.........   WOW , I just read all of the way through this thread, from the beginning.  AWESOME!  this is great stuff arb.  Keep up the good work, I hope that I can acquire half of the skills that you have amassed, in my lifetime.  This is just encouragement for keeping up my build.

[arb]

Thanks man :-D  It has been very fun for me. I used to turn wrench for a living, but computers and then computer security became my bread and butter.

Somethings I have learned - these engines last a life time, or at least a couple generations. The German engineers (I have worked with mercedes-benz dudes) are very good at design.  The second thing, slap a turbo on one of these without boost enrichment and all that black smoke my Rabbits used to spew at full throttle becomes extra power w/o extra fuel consumption. And, lastly, 400 hp is really fun, but not required to get you to and from work. 70 - 90 hp is plenty for my 4000 pound car with manual steering :-p

[peacedub]

very nice write up man, iv always wated to put a TD in a caravan!

you shud post some pics of the van!

cheers.

[arb]

I think I post one of it in the snow, and a few partials of it. Its a second gen caravan who's only 3 attributes were - It was from Virginia so no typical Michigan salt induced rust, it was paid for years ago and was only $400 or so, and it has a factory stick !!

I need to bump all the dents and put a decent paint job on it this summer. Then I'll post some pics.

[NintendoKD]

Where in VA, I'm from there, Franklin CO. "moonshine capitol of the world "  we do tend to be a bit rough on the body

[arb]

Where in VA, I'm from there, Franklin CO. "moonshine capitol of the world "  we do tend to be a bit rough on the body

I think it was Franklin Co !!  Some Russian guy brought it up here to Michigan.

[NintendoKD]

*quickly checks in the mirror*....... *relieved sigh*  No, wasn't me.  Good stuff though, small world.

[arb]

Well, my third inner right used CV joint failed Wednesday. The diesel was doing great until I was almost at work Feb 3... I even took a car load of people to the auto show 2 weeks back... So, I just got off the expressway at Rotunda and stopped at the light. When it turned green, I tried to go and there was the tell-tale pop sound and slight lunge of the CV joint failing. I shutdown, and checked under the hood - same one as the past 2 times - both were used ones I had laying around the garage. Maybe I will pop for a new one this time... Just as I was looking under the hood, Dearborn PD had pulled up behind me. Crap, I had no money for a tow truck, and if he wanted to be a hard a--, he could have said "Are you calling the wrecker or am I" - since he would have had too, it would have been a police impound costing at least double and being twice as hard to get out...
 
Lucky me, he asked if I wanted him to push me down the road to a Ford owned land :-D YES !!!! Its a large sun flower field next to the proving grounds. When parked, he asked if he could give me a ride !!! He was now in Allen Park (some very unfriendly cops there) and I realized I forgot my iPhone that morning... so he took me to work in the front seat of the squad car.

I had one more compete used shaft rapped in plastic. Hummm. Maybe I save the cash for now..

I removed the offending shaft
<a href="http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5639.jpg" target="_blank"><img src="http://i533.photobucket.com/albums/ee338/the_arb/th_100_5639.jpg" border="0" alt="Photobucket" ></a>
and found the end of the spline had no more place for a Sir Clip.
<a href="http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5640.jpg" target="_blank"><img src="http://i533.photobucket.com/albums/ee338/the_arb/th_100_5640.jpg" border="0" alt="Photobucket" ></a>
So I decided to install the last used CV I have as I would weld it to the end of the spline - maybe the other 3 failed due to the Sir Clip coming off. It took quite a bit of blows from the brass hammer to get it on. I had to use a socket to tap it all the way on the spline.
<a href="http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5642.jpg" target="_blank"><img src="http://i533.photobucket.com/albums/ee338/the_arb/th_100_5642.jpg" border="0" alt="Photobucket" ></a>
One possible problem - only 250 pounds of argon left !!!  Should be enough.
<a href="http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5644.jpg" target="_blank"><img src="http://i533.photobucket.com/albums/ee338/the_arb/th_100_5644.jpg" border="0" alt="Photobucket" ></a>
Here is it all welded up.
<a href="http://s533.photobucket.com/albums/ee338/the_arb/?action=view&current=100_5645.jpg" target="_blank"><img src="http://i533.photobucket.com/albums/ee338/the_arb/th_100_5645.jpg" border="0" alt="Photobucket" ></a>
YIKES !!!!  I did not try to locate the failed Sir Clip !! I hope it was not stuck in the grease on the trans hub !!  I'll have to search the wreckage tonight. It could be in the boot or with the failed CV.

[theman53]

That is awesome that he helped you out. I hope you figure out the CV eating problem. It wasn't at that bad of an angle to constantly be killing these is it?

[rabbitman]

That's actually pretty neat, it's nice that cops help out every now and then. After all they're supposed to be public servants..........