CV Joints - General Information, Removal, Installation, and Maintenance

Parts

Part Number	Description	Application	Qty
944 331 901 00	CV Joint Kit	1977–1988 924/S/T; 1983–1991 944/S/S2; 1986 944T	4
951 332 901 00	CV Joint Kit	1987–1991 944T	4
944 331 903 00	Boot Kit	1977–1988 924/S/T; 1983–1991 944/S/S2; 1986 944T	4
951 332 901 00	Boot Kit	1987–1991 944T	4
477 501 103	Axle – Manual Transmission	1977–1985.5 924/T, 944	2
477 501 101A	Axle – Left Auto Transmission	1977–1985.5 924, 944	1
477 501 102A	Axle – Right Auto Transmission	1977–1985.5 924, 944	1
944 332 038 01	Axle – Manual Transmission	1985.5–1991 924S, 944/S/S2; 1986 944T	2
951 332 038 02	Axle	1987–1991 944T	2
944 332 038 02	Axle – Left Auto Transmission	1985.5–1991 924S, 944	1
944 332 038 03	Axle – Right Auto Transmission	1985.5–1991 924S, 944	1

Tools

• 8 mm 12-point internal (cheesehead / triple-square) tool

Tip: The 8 mm 12-point tool is available at major auto parts stores. It is also used on the pressure plate-to-flywheel bolts. A 10 mm version is used on the camshaft sprocket bolt and a 12 mm version on the flywheel-to-crankshaft bolts. The Snap-On version is marketed as a "triple square" socket.

• Metric socket set
• Channel-lock pliers
• External snap-ring pliers
• Paint marker or bright-colored nail polish
• Punch
• Hammer
• Solvent (mineral spirits or brake cleaner)
• CV joint grease (molybdenum-based)
• Rags

General Information

CV joint maintenance is an important part of any routine check. Failing CV joints typically produce a clicking sound from the rear of the car that can be localized to one side. The click may appear during normal driving or in a turn on the outside rear axle.

A clicking CV joint can often be repaired by simply removing the axle, cleaning the joint, and repacking with fresh grease. Over time the grease in a CV joint tends to diminish even when the boot is intact.

If a joint is damaged, options include: individual CV joint kits from Porsche, complete new or rebuilt axles, or a boot kit if only the boot is at fault.

Procedure

1. Place the rear of the vehicle on jack stands and block the front tires.
2. Using a paint marker or nail polish, mark the orientation of the drive axles before removal.

Tip: If re-greasing, there will likely be old grease caked into the cheesehead bolt recesses. A power-wash or brushing with solvent before attempting bolt removal significantly reduces the risk of stripping the bolt heads.

3. Using the 8 mm 12-point internal tool, remove the cheesehead bolts at both ends of each axle (transaxle end and wheel hub end).

Note: It will be necessary to prevent the wheel from rotating while loosening the bolts. Options: place a block under the wheel, lock the wheel with the parking brake or by engaging a gear, or have an assistant hold the wheel.

4. When all bolts are removed, carefully lower the drive axle from the vehicle onto a clean working surface.

5. Use a punch and hammer to tap gently around the outside edge of the CV joint collar to separate it from the CV joint housing.

6. Wipe all grease from the end of the CV joint. Using a paint marker or nail polish, mark a line from the center shaft across all components to the outside edge.

7. Using external snap-ring pliers, remove the circlip at the end of the drive axle shaft.

8. Push the shaft out of the CV joint. If stubborn, tap the end of the shaft with a flat-tip punch and hammer.

9. Remove the concave washer from the axle shaft; use channel-lock pliers if necessary.

10. Slide the boot off the end of the drive axle shaft.

11. Turn the inner race until the balls align with the grooves in the outer race, then tilt the inner race to separate the two races.

12. Push the ball bearings out of the inner race.

Note: Keep all parts from each CV joint together. Do not mix parts between joints.

13. Clean all CV joint parts (races, splines, ball bearings) with solvent and inspect for damage. If any part shows excess wear or cracking, replace the entire CV joint.

14. Apply a small amount of grease to the ball bearing grooves on the inner race. Using your fingers, press the ball bearings back into the inner race until they snap into place.

15. Assemble the inner and outer races by aligning the ball bearings with the grooves and tilting the inner race into the outer race.

Tip: If inserting the inner race with ball bearings intact is difficult, try an alternative method: remove all ball bearings, insert the bare inner race into the outer race, tilt the inner race, and install the ball bearings one at a time.

16. Inspect the CV joint boot for rips, tears, or wear; replace if necessary. Apply a small amount of grease or silicone spray to the axle shaft opening of the boot. Slide the boot onto the axle and apply a small amount of grease inside the boot.

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

18. Thoroughly repack the CV joint with grease.

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

20. Check the alignment marks on the axle shaft and on the CV joint inner and outer races. Slide the CV joint onto the axle with all marks aligned.

21. Install the circlip on the end of the axle shaft to lock the CV joint in place.

22. Tap the CV joint boot collar into place on the CV joint.

23. Reinstall the axle into the vehicle.

24. If any cheesehead bolt heads were damaged during removal, replace with new hardware. Install all bolts on both ends of the axle finger-tight first.

25. Using the 8 mm 12-point internal tool and a torque wrench, torque the cheesehead bolts to 30 ft-lbs (42 Nm). Lock the rear wheel during torquing.

26. Remove the vehicle from the jack stands.

27. Test drive the vehicle, starting slowly and gradually increasing speed while listening for unusual noises.