On my recently purchased 1996 Audi A6 Quattro wagon the left front outer CV joint had oversize ***** which were wider than the slots in the CV joint cage. I took my die grinder and widened the slots so the ***** would not bind.
Perhaps there are some CV joint rebuilders who just put in oversize *****, but don't check the width of the cage slots.
The CV boot was badly torn. I had a lot of trouble taking this joint apart, as compared to a normal joint. I had first thought that it was just very dirty grease.
When putting a CV joint together beware of putting the cage in backwards.

 

You just added reason # 34.5 to my list describing why I always do rebuilt axles instead of trying to change CV joints or boots. Costs a bit more but it certainly causes less pain.

 

The previous owner had a rebuilt left front outer CV joint installed instead of just replacing the boot. What he got was an improperly assembled CV joint with oversize *****, which may have come from a junkyard.
Why go for an improperly rebuilt junkyard axle when you could buy a new outer CV joint. The reason is that a cheap shop can make more money by using a cheap rebuit axle. As long as the CV joint doesn't make any loud noises and lasts 90 days the cheap shop is happy. Nicely painted, the axle looks new.
So, one of the reasons that CV boots may fail is that there may be something wrong with the CV joint, such as being too loose or too tight. A used CV joint may be worn irregularly, so an oversize ball be too tight at an unworn spot and too loose at a worn spot.
Hence, if you want quality, then either buy new CV joints or verify that the rebuilder has a good reputation.

 

Very truthful!!!

There is a very easy way to reuse the wrong *****, having all ***** for the day in a bucket for cleaning. Plus redoing the surface thermal finish => and having rock bottom pricing???

There are re- builders all over that are in the business to make $$$ only.
A friend of mine went down the road using rebuild shaft for replacement. After 3 attempts to accommodate different rebuild shafts he did the effort to pay a visit to a rebuilders shop.
I'll save the details=>since he never uses rebuild shafts.

 

I have put rebuilts shafts into a 88-90Q, 89-200 QT, 95-A6 and a 97-A6 and know of at least 8 others that have done the same without a problem. I guess it dependends where you get them from.

 

The guy that we take all of our used VW/Audis to for service always has ours rebuilt with oversized *****(oversized due to the grooves cut out by the previous ***** due to lack of lubrication) for a tight fit. I have had great luck with them. I think the problem was that you said he replaced the CV and not the boot, that sounds like the real prob.