Mk1 Inner CV Boot FULL of Tranny Lube ?

[theman53]

Yeah, I am confusing:D

My kit came with the little seals and the flange seals. In the peliquin kit it has metal little seals and I went that route and don't remember how they install. Let me know if you need the little pieces and I can ship them out still.

[Baron VonZeppelin]

The driver axle was a breeze getting it out.
Flange Cap still in place - but sort of think it might have leaked some. idunno.

Grease looked iffy, and smells more like tranny lube than grease.

Boots are getting stiffy'ish and can find some exterior crackage starting. What the friggn heck ... replacing driver side too.

I need some advice on what is going on with passenger side flange - i think it is the remnant of the old flange cap. But don't wanna tear it out if its something else that needs to stay.
Not touching it yet.

Took pix of both flanges.
PM'd Vincent about sending them to him for advice, and maybe posting them to this thread. I can't post pix to pic-hosters due to my turtle-charged ISP. They don't cooperate.

And need advice on going about removing the intact driver side flange cap.

I have some #2 Permatex non-hardening.

And last question for now ...
Manufacturer calls for 174 ft lbs torque on axle nut - what does Bentley say for Mk1 ?

Mk2 says 195 ft lbs

Before the end of this month - I have to drive this rig up to TylerTown in Canada, and back, with some extra metal onboard. Need some road time between now and then to gain confidence and peace of mind. 

[burn_your_money]

Seal removal

http://www.brokevw.com/pic%20205s.jpg

http://www.brokevw.com/pic%20206s.jpg

Go for 195

[theman53]

after now meeting the broke vw he does wear those gloves to touch all trans pieces

[Baron VonZeppelin]

Thanks for that Tyler.  ^5

I forget about Broke's site too often.

The new passenger side shaft from AdvAuto is too short.
I just compared them a while ago.
Old shaft is approx 30 and 3/16 inches (approx 767mm)
New shaft is approx 29 and 1/2 inches (approx 749mm)

WoW

Looks like i'll be checking out the reman'd shafts at CarQuest tomorrow. %#@!&

BrokeVW must have gotten tired of having nasty looking hands 24/7/365. Gloves are worth every penny. I use clear vinyl ones - "most" of the time.

[theman53]

You can't pull the extra 11/16" on the inner? I never measured my new 100mm I just stuck them in there. Reminds me I still need the passenger side. BTW I have a "good" passenger side cv shaft 90mm if you need it to get on the road. It is still on the car, but unlike the driver's side that had a tear in the outer the passenger side is good:D You probably want to get a good new one, but I am just trying to help and make some money for the money pit jetta:D

[Baron VonZeppelin]

Thanks for the kind offer theman53.
But yeh, i'm wanting new stuff while i'm going through it.

Idunno why this new one is so much shorter.
Could be defective merchandise.

Or maybe the chinamen figured out a way to get more length from a shorter shaft.

I stood them on the axle nut ends side by side, and kinda freaked out on the difference. Seems like by the time that much difference was made up, there wouldn't be anything left for suspension travels.

Or maybe the one that came off my truck is Too LONG.
And maybe that busted the axle flange cap off ..... hmm
Bit of a quandry now.

CarQuest had a driver side, and will have a passenger side in the morning.
I'll get a measure from their passenger side and see where the clues lead.

I have it set up where i can end up with a pair of new from AdvanceAuto - or a pair of reman'd from CarQuest - in hand by lunchtime Friday - either way.

My driver side is approx 21 inches (approx 533mm)

[Vincent Waldon]

Some pictures of the offending bits:

[Baron VonZeppelin]

Thanks for handling those pix Vince.
The little yellow/green plug in one shot in center of flange was a plug a put there to keep bugs out.

The reason the old shaft looks nice is because i painted it along with a lot of other under garments about a month or two ago. It was previously a solid coat of surface rust and road grime.

The offended flange shows to still have some of the Cap glued or heat welded - intact around perimeter. There was a small piece of black plastic stuck inside the inner flange bolt hole. Probably a piece of the busted Cap.

My wipe off rag had a fair amount of small metallics after wiping the flange.
One of the big ball bearings fell out in the catch pan while i was wiggling the joint around to start removing the shaft. So i went ahead and plopped the other 5 out and put them in the catch pan too.

At least one of the recesses for the ball bearings has heavy wear.
That was enough that i didn't check all of them, for now.

[Baron VonZeppelin]

CarQuest and WorldPac came through for me today.
Got new axle caps in hand.

The reman'd axle shaft is same length as the new one from AdvanceAuto - approx 29.5"

So i'm going to have to conclude for the time being that the pre-existing shaft was incorrect. Maybe Scirocco or Mk2 application ?
ellifino ...

Which makes me think it caused itself to bust out the Flange Cap on that side.

I have to start with putting in the Driver side shaft first because that side is shaded now. And its about 95* out there. Might get them both done by tonight, and maybe not.

I'm going with the New shafts that came from AdvanceAuto.

[burn_your_money]

The passanger side on a mk2 is longer then the passanger side on a mk1. The drivers side is the same length. Scirocco is considered mk1.

I don't have any passanger side axles so I can't measure one for you.

[Baron VonZeppelin]

That would be good if someone had a loose passenger side Mk2 to measure. HeckFire - i might order one and return it just to measure it if i have to !! LoL

I read so much stuff, sometimes it gets fuzzy in my noodle.
Thought had read that rocco axles were diffy, but maybe that was just the flange size - not the length.

It would sure be comforting to know if Mk2 length matched this pre-existing axle. Would help explain things better.

For now - i'm going forward since 2 diffy sources supplied same length replacements.

You guys have been a BIG Help !   

[burn_your_money]

Turns out I do have a mk2 axle. 30 1/2 is what I measured tip to tip with the inner CV compressed so I was measuring off the end of the shaft.

[theman53]

Just a thought.
Did the MKI have different a arms and ball joints than MKII? I think the spindle if nothing else will be different. Might want the MKI CV.

[Baron VonZeppelin]

It's got Mk1 shafts in it now.  

Just wanted to measure mk2 shaft to try and figure if this 30+" shaft might have come from/been for/ an mk2.
I'm almost certain now that it did.

Thanks for digging that one out Tyler !

While i was working - the noodle blinked a lil bulb (twinkle):
The TD garments on the engine, and the ACH tranny, both came from the same 85 Jetta. They probly used the 85 Jetta axles too - without checking length - or thought it was close enough to work okay if they did compare.

I sent a couple more pics to Vince, if he gets to post them.
After removing the offended Flange Cap and checking it out - it has been "machined" out in the center - not knocked out. So the axle did the machine work on it. The backing on the Flange Caps is metal.

Got the axles in with the tripsquares all at about 10lbs.
Axle nuts are just run on to the oblong point.
Ball joints are torqued.
Will do final torques on axles tomorrow, had enough fun for one day.
Save some for tomorrow .....