Noisy Axles, Is there a trick I don't know about? Options

[John]

This past weekend, I did my first track event of the year (have been doing them for the last 18 years).

I started hearing a clunking noise from the rear. It sounded like it was coming from the Left Rear (Driver side). I checked it out and the only thing I could find was that if you grab the axle shaft and vigerously shake it side to side, the axle shaft will bottom out and cause the clunking sound I am hearing out on the track.

What I believe has happened is that there is no grease left at the end between the stub shaft and the end of the axle to cusion the shaft movement.

Here is part of my problem. I bought the axle shafts from Patrick Motorsports 2-3 years ago when I did the 915/916 transmission, and they are different axle shafts. The stub shaft is connected to the CV joint and the other CV joint (tranny end) has a sealing cap crimped to it. I don't know if it is perminantly attached, or if it comes off.

Are the axle shafts worn out when you can move the axle shaft like this, or do they need grease. If they need grease, how do I get the grease in where I think they need it?

The only changes I made to the rear suspension this winter was to lower it about 3/4" (axle shafts are horizontal), increase the spring rate from 350# to 400#, and align it. I have checked everything out and nothing is loose.

Any ideas, suggestions, or wisecracks welcomed.

[John]

No there were no dimples or dents in the caps. They looked good to me, so I put them back in.

We had another DE this weekend Fri, Sat, Sun.

The car still made some of the noises, but it was not as bad.

The clunking is not noticable under power, but under light power or coasting through a turn, the clunking returns. While at speed and pushing the car hard, no clunking noise is noticable.

This is a weird problem and even Patrick Motorsports does not have a clue as to what this might be caused by.

I guess that replacement of these 911 axles will be necessary, but it seems like these did not last long at all (these are only 3 years old).

When I know new ones have been ordered, I will probably figure out a way to remove the caps and rubber boots to try to inspect the actual CV joints themselves. It sure feels like the CV joints are very loose (especially on the stub axle side).

Any suggestions as to how I should try to get the caps or the rubber boots off of the CV joints?