I did not have an intention to write a how-to in the first place. The pictures were posted for knowledgeable people to see what I am doing and correct me IF I did something wrong along the way, and also for others to learn from my mistakes.

Now that the project is complete, I organize everything, reduce the size of the images, and upload them to the site.

 

or so I thought.

While replacing my front rotors and brake pads today, I noticed grease all over the passenger's side wheel well! One of the re-manufactured CV axles that I installed not so long ago had a torn inner boot. I guess, hose clamp cut through the rubber.







Detroit Axle offer life time warranty on this product (Front Passenger Side CV Axle Shaft w/o ABS for Automatic Transmission ONLY - USA Made - Lifetime Warranty - Detroit Axle). It is just a major PITA doing it all over again on the passenger's side.

Now I have to be very careful taking the stub shaft off without damaging the sleeve. I'll just follow donbrew's advice and use a muffler clamp (http://www.autozone.com/emission-con...uestid=5821765) and a small hammer. Bearing splitter (http://www.harborfreight.com/large-b...ator-3979.html) is a little bit pricey, but seems to be a safer option. Buy, use, return is another option.

 

If you still have an old axle around, count the folds on the boot. I had a set that fit, but 1 less fold makes a difference, both blew out in no time. I seem to remember 5 or 6 was the number, yours seems to have 4. You could go to Advance/Zone and look at one they have in stock.

 

I still have the old ones laying around in my garage. Yes, it has 5 folds! The new one has only 3 folds. Are you saying that the old boot can be reused and the inner joint repacked with grease? I wounder if I need to take out the entire axle assembly out to do this? I begin to dislike Detroit Axle for some strange reason.

 

Thing is you only save about $5 with them. I ended up at Zone, for $69 ea., IIRC. In stock.

IF you can find a new boot, you will need to pull the axle. They used to make a 2 part boot for VW that bolted together.

If it doesn't have 5 folds it will break, the suspension flexes too much.

 

I just checked other manufacturers of CV axles and they all have 3 folds on their inner joint boot (2011 CHEVROLET HHR 2.2L L4 Drivetrain Parts | RockAuto). It looks like mine just came damaged from the start.

Buying another one will not make a difference. I will just try to sort things out with Detroit Axle. In the worst scenario, I am covered by eBay buyer protection plan.

 

You don't usually have to go to eBay protection, but any one with only 3 folds will fail quickly.

Look at the first photo for the why. It is not the clamp cutting it, it's the flexing.

$65 at Zone $70 at Advance; coupons available online.

 

Autozone sells only Duralast products. Here is the only one that fit HHR. It is exactly the same design as the one I got from Detroit Axle. Which $65 one are you talking about, donbrew?


Duralast Gold CV Axle 9553N- Read2Reviews onDuralast Gold #9553N

 

The question is: is that a stock photo? Maybe it has to do with the length of the shaft, not the total length?

I just went to both web sites and looked in my zip code for in stock HHR axles. Cheaper brands by mail. That one is $64.99 in my Zone.

Not recommending anything, but this one looks like the Factory OE. There are lots of others. I had assumed they fit lots of cars, but only GM Delta.
CV Axle Constant Velocity Driveshaft See Compatibility Chart for Location | eBay

It was a long time ago for me; maybe it was the outer boot that split on mine. I do remember I noticed when I took them out of the box.

 

These CV axles are remanufactured and they cost as much as the new ones. Interestingly enough, the company that sell them is 15 minutes away from my house. But I am a bit hesitant to buy things from companies with little or no reputation. I'll wait for Detroit Axle to reply.

If I keep having problems with their axles, it will be a lesson learned for me and also a documented case for everyone else to learn from. It may be just my luck that I got a defective axle.