Might have a failed CV joint...
 

Last summer I replaced both front axles/CV assemblies with brand new -- not rebuilt -- ones from NAPA.

Last night my son called and said that he had a serious sounding rattle in his engine compartment. Just as he pulled into our drive the engine stopped and wouldn't restart. The engine would just barely attempt to turn over. My assumption was that the alternator had failed and running with lights and AC had run the battery down.

This morning I removed the serpentine belt and found that the alternator was completely frozen. The back side of it had spun out some metal slivers around the shaft. Things looked pretty clean around it -- no oil or grease.

Directly below that was not the case. The area completely around the CV boot was packed with thick gray/black grease.

I couldn't see anyplace where I could be sure that it was coming from but it had the same appearance as when any rotating greased fitting spins its grease out. I carefully cleaned everything assuming that I would find a damaged boot.

The boot is tightly sealed on both ends and there are no tears anywhere. I can feel a slight looseness in the CV joint itself but only very slight.

I've never looked inside one of these and have always assumed that the boot was just a dust boot. The big [inside] end of the CV that the boot attaches too doesn't have any indication of a crack or break and the grease that appears to have been spun out seems more centered over the boot itself.

Has anyone had any experience with this kind of symptom and, if so, was it the CV and, if so, how the heck did that much grease get out without any detectable tears or looseness?

While I've got it opened up to change the alternator would be as good a time as any to replace the CV if that's what I need to do but I'd like to at least know that's likely necessary.

Any help?

Well, it only takes a small tear to spin the grease out, Howard. Unless you clean the boot and use a bright light to inspect it, you might not be able to find it. I'd clean it, and gently squeeze each part of the billows and see if you can spot a crack or hole. Under centrifical force the split would enlarge and then sling the grease out. I'd just remove the frigging axle and take it back to NAPA for another one. I'm presuming you got a limited lifetime warranty on it, right?

Yeah. Same conclusion I came to. NAPA is overnighting a new one under the warranty.


Thanks for helping me think about it.

Good to hear they sent you a new one.

Well, mystery solved. The clamp wasn't loose, it was gone. The clamp on the big end is completely missing. You can see the indentations where it used to be but now? Nothing, nada, zip, zilch.


I suppose I could fill the boot with CV grease and put a new clamp on but they're already sending me a replacement so I think I'll replace it.


Never had a clamp go missing before.


Again fellas, thanks for helping me thing about this.


Btw, changing the altenator is a bear of a job. All because of one bolt -- the top one. If my hand had been a millimeter thinker I would not have been able to get that bolt off and certainly wouldn't have been able to put it back on. Man, that location is just crazy...

Have them double check the clams on the new one, Howard. That way, maybe the can snug it some if it needs it. They SHOULD have the proper type of clamp pliers.