cv axle problem

[Mattk]

1993 legacy AWD 136K. I was replac frt brakes and noticed torn cv boot on pass side. I pulled axle and replaced inner and outer boots. I followed Haynes and sep the ball joint. Axle was not making any noise under any conditions prior. Reassembled all and it was good for ~2days. then I noticed acliking and pop in wide turns at >10mph. It got worse and I diassembled it all to recheck the inner joint. Put it back together and the popping was worse. I bought a rebuilt axle and it was good for ~2 days and now it is worse again.

I am thinking I 1) screwed up the alignment bad with the ball joint separation 2)There are bad motor/trans mounts or 3) I screwed up the trans somehow. It really sounds as if it is the inner cv joint and the fact that there was no noise before and the rebuilt axle is doing the same thing suggets the problem lies outside the CV joint.

Anyone else have this happen?

TIA
Mattk

[Mattk]

Originally Posted by Mattk

1993 legacy AWD 136K. I was replac frt brakes and noticed torn cv boot on pass side. I pulled axle and replaced inner and outer boots. I followed Haynes and sep the ball joint. Axle was not making any noise under any conditions prior. Reassembled all and it was good for ~2days. then I noticed acliking and pop in wide turns at >10mph. It got worse and I diassembled it all to recheck the inner joint. Put it back together and the popping was worse. I bought a rebuilt axle and it was good for ~2 days and now it is worse again.

I am thinking I 1) screwed up the alignment bad with the ball joint separation 2)There are bad motor/trans mounts or 3) I screwed up the trans somehow. It really sounds as if it is the inner cv joint and the fact that there was no noise before and the rebuilt axle is doing the same thing suggets the problem lies outside the CV joint.

Anyone else have this happen?

TIA
Mattk

I knew I would figure it out as soon as I posted. I did screw up. The upper sway bar mounting bolt was loose by about 203 turns. I vaguley remember loosening this to get the axle out and realized removing the bottom bolt made more sense. I forgot to tighten the upper bolt. After tightening it down now there is no more popping. I did not return the old axle with my new cv boots yet so I am going to swap it out for the driver side where the boots look pretty dried out but are not split yet.
matt