Hi, I'm replacing the outer CV joint and boot on an '85 Golf. At the same time, I've disassembled and cleaned the inner CV joint to put in new grease and a new inner boot. However, on putting the ball bearings into and assembling the inner CV joint, the joint now won't swivel, it's locked up. I've followed Bentley and have the widely spaced grooves on the (outer) housing aligned with the widely spaced grooves on the inner hub. The hub remains pressed onto the axle shaft, The outer housing is on the right way as the metal flange on the boot slips on the back correctly and tightly.The cage hasn't come off the hub either so on chance it's on backwards.
Others in this newsgroup have mentioned this problem and mentioned making sure the parts are aligned. I've tripled checked the alignment of the parts.
The other question is in placing the ball bearings back in, do I press them into the carrier cage or do the bearings sit on the outside (held temporarily by the grease until I swivel the whole thing together when I place the last ball? I've tried placing the balls on the outside of the carrier and also pressing them into the carrier. But either way, the balls don't seem to turn freely when I try to swivel the assembled joint, they seemed jammed in the cage openings. The cage openings don't look like the perfect oval openings as shown in Bentley. The openings in my cage are ovals with smallish tabs on either side of the long edges. The balls have to be pressed through the openings with some force (a thumb).
I initially marked the balls but the 6 balls are hopelessly mixed up now, if that makes any difference. The cage looks symmetrical all the way around, so doesn't seem to be an alignment issue there and Bentley doesn't mention any alignment necessary with the cage.
Would really appreciate any tips on what I'm doing wrong here.
-Tony