FWD Axle not fully engaged, jumped out.

I think your center shaft got mixed up with someone else's on the rebuild line.

It's that, or your new control arm is a bit too long and pulls the joint apart.

There is a problem with the snap ring on the outer end of the shaft. Either its not there, or its not engaging properly when its being assembled.

In reply to chaparral:

I doubt it got mixed up, but it's possible. I've touched nothing in the suspension, jsut removed it to replace the Axles. I only found the split boots when I was doing a front end service on the engine (timing belt, H2O pump, tensioners etc. etc.)

Streetwiseguy wrote: There is a problem with the snap ring on the outer end of the shaft. Either its not there, or its not engaging properly when its being assembled.

It's certainly engaging correctly into the trans as nothing leaks and it clicks home, also the outer has to be engaged as it's held in by the axle bolt through the hub. Also at each end if it wasn't correctly engaged the distance would be too short rather than too long allowing it to pull appart. Or am i missing something?

I guess it's the snap ring.

Tempted to just get one from Rock Auto instead. This started as Rock Auto didn't have the manual trans parts listed a month ago. They do now have the right hand axle which is the one giving me trouble.

Berk it, just ordered one from RA instead. Not ever going back to Dearborn Axle for work.

Now, watch the new one come apart on me and make me apologize to Dearborn Axle

The splines that are coming apart are from the shaft to the outer joint. There are a couple of different designs on the Volvo, one of which takes a special tool and a couple of really good whacks from a swinging press. Those are hard to engage, and feel like they are correct. That's not got anything to do with the work you did.

I'd say your rock auto idea is good, as long as the listings are correct. Volvo shafts can be a king sized pain in the ass to get right.

I may have to offer up a Mea Culpa here.

So I didn't even take the axle out again before just ordering a replacement from Rock Auto. As an aside, the new part from RA arrived less than 24 hours after ordering for only $7 standard shipping. Amazing turnaround. I swapped it out this weekend. Now, first time round I'm 100% sure everything was correct and it wasn't my fault, but I may have been at fault this time round.

Once I started stripping it down I found that the bolt through the outer bearing that holds the end of the axle in the hub had backed out. I may not have torqued it up correctly (only 35NM +90 degrees) That's a really low torque setting if I didn't add the 90 degrees and unlike the first time where I changed the bolt, this time I re-used it.

Now, the only thing I can think of with this bolt loose is at low speed full steering lock (parking maneuver) with the CV joint at high articulation, is it possible for the end of the shaft to have tried moving inboard and overextending the CV joint so it came apart? I'm not 100% I'm at fault and want to ask the peanut gallery before I blame the rebuilders a second time? Could this be the issue? I can’t see how the shaft could have moved in, even if loose under any other circumstances, but I almost want to be at fault here.

As I said, I was 100% not at fault first time, but I'm willing to entertain the fact that I could be 2nd time.

As an FYI, the new part I ordered from Rock Auto I assumed would be a re-man part, but it appears to be brand new in every way. The only downside is that it's a slightly smaller diameter than the OEM part, but if it gets me through the next six month I'm happy. I'll be taking the car off the road again in the spring when the Porsche comes out of hibernation and it will be getting a full suspension re-fresh, new shocks, springs and any bushings or links that are worn. If people think it was my issue 2nd time, I'll rebuild the OEM axle again and re-fit it at that time.

Opinions please?

I'd really like some input on this to see if it was my fault. This is the bolt I'm talking about, into the end of the axle shaft.

The spline popped out of the joint again? That bolt will not have anything to do with the spline coming out of the joint. Clean up the spline area and post up a picture of the snap ring area, and the center of the CV joint.

In reply to Streetwiseguy:

Will do.