Flange Wear from CV Joint Options

[frank_c]

Today I started the process of dropping the engine & transmission so that I can send the transmission off to Dr. Evil and take care of some misc engine work (rear main seal, oil return tubes, etc. ). As part of this work I was also hunting for a clunking noise I hear from the back when the car is stopped and as I let the clutch out and the car just starts rolling forward. I already checked and/or replaced all suspension and engine mounts, as well as the outer CV joint bolts (inners are safety wired) and found nothing loose. So next on my list was either the CV joints themselves, or possibly loose flywheel bolts.

When I removed the inner CV joints from the transaxle flanges, I was surprised to see some pretty deep gouges in the flanges from the CV joint inner race/star (see photos below). This seems like a good candidate for the noise I am hearing.

I have never seen this type of wear before with any of the other cars I've worked on - what would cause this? I noticed that there is not much grease in the joints, which I suppose is one possibility. Was the inner race put on backwards? Wrong parts? I did confirm that the axle shaft does move in and out freely at the outer CV joint.

Thanks for any insight.

Left flange:


Right flange:


Circled area shows where inner race is cutting into the flange.

[Jack Standz]

It is a rare but I have seen in before in stock axles.

Me too.

Not what you could call "normal" wear, but have seen similar wear like that on an old/used 914 transmission flange. If the flange is going to be reused, it shouldn't have any negative impact because your CV, when in normal condition shouldn't contact the flange there. Interested to see the wear on the CV or condition that caused this.

The problem now is how to get replacement CVs if that's the plan. Go with 911 axles (930 CVs) with adapters from PMS? Or PMB has these:

https://pmbperformance.com/products/porsche...84588&_ss=r

[frank_c]

The problem now is how to get replacement CVs if that's the plan. Go with 911 axles (930 CVs) with adapters from PMS? Or PMB has these:

I've seen other posts mentioning that the OEM CVs are NLA, but I see that both Pelican and SMC have them listed as available. What am I missing here?

https://www.pelicanparts.com/More_Info/91433202903.htm

https://sierramadrecollection.com/products/...-914-332-029-03

[Superhawk996]

The problem now is how to get replacement CVs if that's the plan. Go with 911 axles (930 CVs) with adapters from PMS? Or PMB has these:

I've seen other posts mentioning that the OEM CVs are NLA, but I see that both Pelican and SMC have them listed as available. What am I missing here?

https://www.pelicanparts.com/More_Info/91433202903.htm

https://sierramadrecollection.com/products/...-914-332-029-03

(IMG:style_emoticons/default/headbang.gif)

Oh boy - here we go again.

Those joints are for the 914/6 splines and will not fit 914/4 axles (different spline counts)

Porsche has (IMG:style_emoticons/default/sheeplove.gif) the pooch on their part numbering, and none of the suppliers care enough to address the issue and keep selling the wrong parts. Search the forum and you’ll see this issue is well documented since about 2019.

I have a set of 914/6 axles and have purchased those joints and have confirmed what they fit.

Not maybe the situation has changed . . . But doubt it. Call PMB (not affiliated)

[frank_c]

First, I want to say thank you to everyone who has chimed in here to help identify what might be going on - I really appreciate it. I've owned and worked on 911s for decades, but I'm only about a year into climbing the 914 learning curve, so still much to discover. Btw, my Patron badge is not up yet, but I did make a contribution about a week ago.

Those joints are for the 914/6 splines and will not fit 914/4 axles (different spline counts)

Ah, OK. It's surprising that this has been an issue for so long and it has not been corrected yet. Thanks for saving me from ordering the wrong parts. This makes the decision to go with the assembled units from PMB an easy one - easy button it is (IMG:style_emoticons/default/smile.gif). If it turns out that my axle shafts are indeed too long, then I suspect I won't be able to use them as my core return to PMB - but I'll call them if that situation arises.