CV Joints – Installation

Overview

This guide details the steps to install Constant Velocity (CV) joints and drive axles on a Porsche 944 with a 16v engine. Proper installation ensures the CV joints function smoothly, transferring power from the transaxle to the wheels without noise or vibration. This procedure covers assembling the CV joint components and reinstalling the axle, assuming the joints have been cleaned, inspected, and repacked with grease as needed.

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Tools Required

• 8mm (5/16 inch) 12-point internal tool (also known as a “cheesehead” or “triple square” tool)
• Metric socket set
• Channel lock pliers
• External snap ring pliers
• Punch
• Hammer
• Deep socket (appropriate size for axle splines)
• Torque wrench
• Rags

Parts Required

• CV joint grease (Moly-based), Not specified
• CV joint kit (if replacing), 944 331 901 00
• Boot kit (if replacing), 944 331 903 00
• Cheesehead bolts (if replacing damaged bolts), Not specified

Step-by-Step Procedure

Step 1: Assemble the CV Joint

1. Apply a small amount of Moly-based CV joint grease to the ball bearing grooves on the inner race of the CV joint.
2. Press the ball bearings into the inner race using your fingers until they snap into place. Keep components from each CV joint together to avoid mixing parts.

3. Align the ball bearings with the grooves in the outer race and tilt the inner race to insert it into the outer race. If difficult, remove the ball bearings, insert the inner race, then add bearings one at a time while tilting the inner race.

4. Verify that the inner and outer races are securely assembled with all ball bearings in place.

Step 2: Install the Boot and Washer

5. Inspect the CV joint boot (944 331 903 00) for rips or wear. Replace if damaged.
6. Apply a small amount of grease or silicone spray to the axle shaft opening in the boot, then slide the boot onto the axle.

7. Slide the concave washer onto the axle splines. Use a hammer and deep socket to tap the washer fully to the bottom of the splines.

Step 3: Attach the CV Joint to the Axle

8. Thoroughly pack the CV joint with Moly-based grease, ensuring all components are coated.

9. Apply a small amount of grease to the axle splines.

10. Check the alignment marks made during removal (using paint marker or nail polish) on the axle shaft and CV joint components. Slide the CV joint onto the axle, ensuring all marks align.

11. Install the circlip on the end of the axle shaft using external snap ring pliers to lock the CV joint in place.

12. Tap the CV joint boot collar into place on the CV joint using a punch and hammer, ensuring a secure fit.

Step 4: Reinstall the Axle

13. Position the axle back into the vehicle, aligning it with the transaxle and wheel hub, using the orientation marks made during removal.
14. Install the cheesehead bolts (Not specified) on both ends of the axle (transaxle and wheel hub), tightening them finger-tight first. Replace any damaged bolts with new ones.
15. Use the 8mm (5/16 inch) 12-point internal tool and a torque wrench to tighten the cheesehead bolts to 42 Nm (30 ft-lbs). Hold the wheel steady (using a block, parking brake, or assistant) to prevent rotation during torquing.

Step 5: Complete the Installation

16. Lower the vehicle from the jack stands after ensuring all bolts are torqued and the axle is secure.
17. Test drive the vehicle, starting slowly and gradually increasing speed, listening for unusual noises like clicking to confirm proper installation.

Post Procedure Checklist

• Confirm all cheesehead bolts are torqued to 42 Nm (30 ft-lbs) and secure.
• Verify that CV joint boots (944 331 903 00) are intact and properly seated with no leaks.
• Check for smooth operation and no clicking noises during the test drive, especially in turns.
• Ensure all tools and debris are cleared from the work area.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube