It is possible to assemble the CV joint improperly. This can cause excessive
binding and might have been the reason the axle sheared.

Chris DeLong
Fine Tuning
206.522.5503
www.finetuningperformance.com
Seattle, WA USA

>From: Tim King <yellowdog@SOFTHOME.NET>
>Reply-To: Tim King <yellowdog@SOFTHOME.NET>
>To: vanagon@GERRY.VANAGON.COM
>Subject: SNAP! Zrrrrrrrrrrrrrrr! (sheared CV axle shaft)
>Date: Mon, 30 Aug 2004 13:37:30 -0700
>
>So, I'm minding my own business starting out from a stop in my van, and I
>hear the above mentioned very loud sound, and no longer can move (without
>difflock that is).
>
>First thought is, Oh, no, not my tranny again. My buddy hops out, looks at
>under the van and says "you busted your CV joint."
>
>I'm thinking that's weird because I just bought brand-new, rear CV axles
>(empi made from bus depot). He takes a closer look and says, "uh, the whole
>shaft broke!"
>
>Yup, true tale. The driver side axle shaft sheared in half right under the
>tranny side boot. It looks like it was laser cut it's so smooth. Anyone
>ever seen this happen? Axle had about 300 miles on it. Van is a syncro
>Westy with suby 2.5. I'd like to blame this on the massive power (yeah,
>right) of the suby engine, but I think it's simply a defective axle.
>
>Up until now (300 miles), I've been kind of disappointed with my suby
>conversion. I didn't really want to admit it, what with the added
>reliability, plenty of power, and really cool sucking sound of the K&N
>intake, who was I to complain. Still, the van just hasn't been smooth. It
>kind of felt jerky all the time. Almost like a massively binding VC (except
>that my driveshaft is out of the van). I thought it must be some kind of
>ignition miss (experienced during accel and decel, though I'd notice it out
>of gear, too), but nothing showed up on the OBD-2 software. Bad tires?
>Clogged exhaust? Tried diagnosing all of these things with no luck.
>
>Then the shaft snapped. I borrowed my buddy's car (mmmm... heavily modified
>Audi S6), drove home (thought about leaving him with my broken van and
>keeping the Audi), and got one of my good old axles (note to self: this
>fits the "if ain't broke, don't fix it," rule -- I only installed the new
>axles because I wanted everything to be "fresh" following my conversion.
>The old axles were fine -- the boots were good, and the grease smelled
>fresh). I popped in the new axle and wow, it was a new van. It felt like it
>had more power, it was smooth, and I was VERY happy.
>
>My theory is that the axle had a bend or crack in it from the beginning and
>was wobbling with every wheel rotation. That wobbling was the jerking I was
>feeling.  There was nothing to see -- the crack was under the edge of the
>boot, so I don't think I ever would have found this until it broke.
>
>Ah, I like my van again.
>
>Now what to do about the axles? Anyone had any problems with the BD empi
>axles? Are they strong enough for syncro use? I measured them when I got
>them and I think they are about 1mm larger diameter than stock. What are
>the operational angles of the CV joints? (not that these 200 miles were any
>more stressful than driving around my neighborhood, but I'm thinking long
>term). I have stock springs, but I know lifted syncro drivers pay attention
>CV axle operating angles.
>
>Love to hear some thoughts on this.
>
>thanks.
>
>Tim in Seattle
>87 Syncro Westy, suby 2.5
>
>PS -- Following the axle success, I installed my 225/75-15 Bridgestone
>Revos. I'll follow with a full report later, but these seem to be a very
>quiet, very stable AT tire. John at aircooled.net raves about these and I
>think he's right. At 28.3" I wouldn't recommend them for a stock
>waterboxer, but the suby handles them just fine.

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