I was replacing the clutch on my 2003 A4. I had disconnected the drive shat (prop shaft) and some how during the process the 6 ***** fell out of the drive shaft cv joint. How do I reassemble it? Please help. This is the last thing I need to fix.
Thanks

 

It is a PITA to reassemble. Basically you need an extra set of hands. Then put the ***** back into the cage one at a time and hold them there while forcing the outer race (housing) back over them all. Easier to do if you undo the boot clamp, remove the snap ring and pull the joint off the shaft first. Then you can work at a bench without the shaft floping all over and getting in the way. Hard to explain without actually demonstrating it. Biggest problem is it's impossible to get the ***** back to their original postion and you MAY end up with a vibration or premature wear.

 

Does it come off easily once the snap ring is removed or does it require a puller? and should I mark the orientation on the shaft so I can put it back on the same way? So just so I understand all 6 ***** have to be in the cage before the outer race back on? Is there any visual how to anywhere I reference? This is all that is keeping me from hopefully finishing the work on it.
Thanks
Dave

 

Yes, it should slide off fairly easily once the snap ring is removed. You may have to lightly tap on it though. All 6 ***** need to be in the cage and then push the outer housing back on. This is where an extra pair of hands helps a lot. You'll need to start the housing at an angle so basically one ball at a time go into the housing. As I said, really hard to explain just by instruction.

You should mark the position before pulling it off. Most likely not a problem if it isn't the same but if you can, al the better.

Found this that may help. It's describing a Ford Escape rear shaft but it's pretty much the same set up.
Ford Escape Driveshaft separated cv Joint at PTO case, Please HELP. - Ford Truck Enthusiasts Forums