Happy New Year everyone!

I've noticed in the various CV joint rebuilding pages and list posts that no one mentions replacement of the little plugs inside the flanges attached to the transmission.

To clarify: The inner CV joints bolt to flanges which exit the sides of the transmission. When you have the a CV joint unbolted and moved out of the way, clean all of the old grease out of the flange. You'll see a small round plug inside. It covers a circlip that holds the flange onto the final drive. I have found this plug to be leaking on at least half of the Vanagons I've pulled the axles on. Transmission fluid leaks past the plugs, dissolves the grease in the inner CV joint, and ultimately makes a big mess, usually accompanied by the failure of the CV boot. Obviously, the transmission runs low on fluid at the same time.

So buy new plugs for the inside of the flanges which you are exposing by removing the CV joints. They cost a buck or 2. Perhaps a little oil friendly sealant around the perimeter of the plug would be a good idea also. Now you're ready to bolt the CV joint back on.

Alex
living in the VWGULAG