HELP: Axle shaft outer bearing clearance issues, 80 caddy

[Familydiesel]

For my 1980 Rabbit pu, and our 81 Rabbit diesel, I have ordered and tried to install 2 different manufaturers for a left axle shaft assembly and each one I get is about 2 mm too large of diameter for the outer shaft housing.  The clearance is too tight, and when I tighten down the axle nut, the shaft binds in the outer wheel bearing housing (the tapered part of the outer axle shaft part binds with the tapered part of the wheel bearing housing). It won't fit into the tapered section on the outer bearing housing.  Are there 2 different kinds of shaft ends for these?  I keep getting the 69mm ends while the one I have in the vehicle requires a 67mm (measured at the smallest dia. end of the taper closest to the outer bearing housing; the end and smallest diameter of the tapered secton of the outer axle shaft).  I can't find any different part numbers for a smaller diameter one.  All I can find are the larger tapered ones.
Assuming you understand what I am talking about without pictures, do you know of anywhere I can order the smaller dia. shafts or do you have some part numbers that may be of help?
I can use a washer to move the shaft further away from the wheel bearing housing, but I would prefer to just get the right part.  
Here are some part numbers I have tried, that DO NOT work
Beck/Arnley # 1060058, A-1 Cardone #607005,
Thanks,
Familydiesel

[the caveman]

Don't know those brands, but either way ,if you are having that much trouble, you will have to source your shafts from a VW specialist. Don't remember the sizes ,but there are least 2 different sizes for the parts you are looking for.

[R.O.R-2.0]

sure they arent trying to sell you mk2 axles? the inner side will bolt up, but the outter joint is quite a bit bigger than the rabbit parts..

[Familydiesel]

Probably so, since the parts I have received have the same numbers as the MK2's.  The problem is that I cannot find different numbers for the earlier rabbits like mine which don't have the same number as the mk2's.  
There's got to be an easy answer somewhere.  
I could go with a vw specialty vedor I used before, but their parts are almost double, and their shipping costs are too high.
Does anyone know of a moderately priced vw parts vendor which I could contact who would know the difference in part numbers between mk1 and mk2 axle shafts?
thanks

[R.O.R-2.0]

anything that i can help with, prolly wouldnt be of much help to you. because i source most of my parts locally. and i dunno who they use as their supplier..

[8v-of-fury]

sure they arent trying to sell you mk2 axles? the inner side will bolt up, but the outter joint is quite a bit bigger than the rabbit parts..

Not true. I currently have a 91 golf outer cv joint on my 84 passenger axle in my 84, and it fit no problem. a 90mm passenger mk2 axle is about 1/2" too long, but the joints will work on your original axle.

I just clearanced my 81 spindle/hubs/bearing holders to accept a 100mm outer cv joint, and i didnt take off to much material.. If you've already clearanced it..

ALSO you say left axle.. driver side? They are swappable between mk1/mk2. Same length and size.

[R.O.R-2.0]

sure they arent trying to sell you mk2 axles? the inner side will bolt up, but the outter joint is quite a bit bigger than the rabbit parts..

Not true. I currently have a 91 golf outer cv joint on my 84 passenger axle in my 84, and it fit no problem. a 90mm passenger mk2 axle is about 1/2" too long, but the joints will work on your original axle.

I just clearanced my 81 spindle/hubs/bearing holders to accept a 100mm outer cv joint, and i didnt take off to much material.. If you've already clearanced it..

ALSO you say left axle.. driver side? They are swappable between mk1/mk2. Same length and size.

mk2 outters should not fit dude.. none of my cars, even my 84, has weirdo mk1 only CVs.. all my mk2 cars have HUGE outter CV joints..

[8v-of-fury]

I don't see how? I have a 91 passenger outter on my 84 passenger axle right now. in my daily.

I mean even if you have 100mm outters the amount needed to clearance to get them to fit is minuscule. The only problem is if it is a mk2 90mm passenger axle. 1/2" too long, personal experience.

I have fit 100mm to 81 spindles, very little is needed to be ground out.

[8v-of-fury]

Did this get sorted?

[Dakotakid]

What does this guy need, anyway.....does he need a couple of the early outer cv joints which use the clips?
If so, I think I have two brand new Lobros I will never use. Bought them many years ago...when I was quite naive.....

[vanagonturbo]

What does this guy need, anyway.....does he need a couple of the early outer cv joints which use the clips?
If so, I think I have two brand new Lobros I will never use. Bought them many years ago...when I was quite naive.....

This is the information that was missing in this thread. last 3 digits of the early cv joint part number are 099. ONLY an 099 joint will work on the early front spindles. Unless of course you grind away the CV or the spindle. in mid 84 VW switched to using a different style spindle that could accomodate 100mm joints. When this happened, the 90mm outer joints were the same as a MKII. Reman axles are pretty much unilaterally NOT going to work as the outer joints will likely not fit the earlier hub. HTH

[Dakotakid]

Well, it appears as though this guy has fallen off the map.
I believe I have two of these joints (brand new) if anyone wants them. Anyone willing to get a little grease on his fingers, anyway. All this guy seems to have been interested in is R and R.