Peter Badore

So if I understand the failure--the outer cv joint was still held on to the wheel hub by the socket head bolt and the inner joint with its shaft was still attached to the transaxle output flange with 6 socket head screws and the axle shaft just separated from the outer joint? Are you sure that the original axles were the ones that the shop relubricated or could they have been switched for something else? Or maybe the outer joint retaining wire ring was not reinstalled?

thejulex

C-Clip or they installed axles the other way around if you were doing two at once, remember one is a bit shorter than the other one.

Back in days when I had Acura Integra, a shop installed wrong axle on right wheel and it separated couple of miles out of the shop. "The axle looked funny, it was shorter, but we put it in anyway"... that's what I got for explanation. But the body shop was full of cool people, they came with their own truck, towed and replaced again with correct axle again.

Redneck Truck

You understand the failure. The circlip was installed, but may not have done its job. That's the only way I can explain it.

I don't think they switched them out - they look exactly like they did when I dropped them off, same boots, rust, and all. I dropped them off degreased, picked them up greasy, so they at least did that.

SloopJohnB@mac.com

VERY interesting solution!!! Good one!

a62.7t4ceo

2nd EMPI. Excellent quality. You can get a pair for $120. The boots are excellent, too.

Redneck Truck

I'm almost certain I got it right - read derracuda's build and went with what he said. Will verify when I have them both out.

Edd W

Driveshafts and CV joints are extremely robust and rarely need replacing.

It makes more sense to simply repair the one you have now - fit a new circlip and make sure the shaft is fully inserted into the joint. You should be able to see that the centre of the joint is firmly up against the nylon spacer and washer on the shaft. I always try lightly taping the joint while the shaft is still in the vice to see that it does not easily slide off the shaft.

2.7Lturbo

this is why i dont let shops do work, one little thing not done right or replaced can ruin you whole day

Peter Badore

How long had the 6 speed manual axles been in your 4.2 V8 A6? Do you think that the 6 speed axles might be at the limit of their extension in a V8 A6?

Redneck Truck

A little update: I sent the axle back to the shop that did the repacking and they told me the outer 1/4" or so of splines were twisted and the joint wouldn't go back on. Since they gave it their blessing last time and it fell apart, they agreed to repair it (re-tube it?) for free using the outer from one of my old auto shafts, which are the same. I went back and verified, and the axle bears the part number 8D0 407 272 AR, which seems to correspond to a 2.7T RF axle shaft. Not sure why this one fell apart, but maybe the third time's the charm.