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VW MK2 front CV Axle options

Posted by Josh Wimpey 
Josh Wimpey
Josh Wimpey
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VW MK2 front CV Axle options
April 03, 2016 06:09PM
FYI. Doing some research on axle & CV options of MK2 cars.

VW Motorsport apparently modified their cars in the following ways:
--Machined front uprights to accept larger OD wheel bearing from Audi 80
--Ran Audi 80 bearings, hubs and outer CV joints with the bolt rather than the nuts that mk2 outers have.

MK2 Outer CV


Audi 80 Outer CV


So, I thought there might be a shortcut to getting this setup but then looking more closely, it seems the VW stymied us. Namely, the Audi 80 hub and bearing have a step in them from 39mm to 41mm while the VW parts have a diameter of 40mm with no step. So, in order to do what VWMS did you do have to machine the upright or make a custom hub that uses the 40mm ID bearing already in your MK2....

Wheel bearing & shaft dimensions
MK2:
72mm OD
40mm ID
37mm thickness
Hubs drilled 4x100mm
Splined portion of shaft is 22mm OD

Audi 80
75mm OD
39/41 ID
37mm thickness
Hubs drilled 4x108mm
Splined portion of shaft is 25mm OD

Someone else did some calculations showing the Audi 80 parts are 220% stronger.

It seems that Driveshaft Shop may have already made a custom hub to fix this issue that they sell with their "Level 3" axles. But, it sure would be nice to just buy the hubs rather than the $1100 axle kit... Will call them tomorrow to see if they would fit and if they can be purchased separately...



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Edited 1 time(s). Last edit at 04/03/2016 06:11PM by Josh Wimpey.
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Robert Culbertson
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Re: VW MK2 front CV Axle options
April 03, 2016 06:41PM
Are the inner CV teeth the same size? I know they are the same count, but I think they're a different OD. I'll check if I still have the notebook with all my notes. I know I found an Audi one that was close, but the inner splines were way different.
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Josh Wimpey
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Re: VW MK2 front CV Axle options
April 03, 2016 08:18PM
I am not sure. It would be great to have one of each sitting in front of me but I do not.



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ElectroTech
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Re: VW MK2 front CV Axle options
April 03, 2016 08:24PM
Was reading back in some older threads and Derek Bottles had his hubs resplined to work with the DSS axles. Their hubs a built light apparently and wouldn't stand up to rally use.



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ElectroTech
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Re: VW MK2 front CV Axle options
April 03, 2016 08:57PM
Getting hubs resplined isn't a major operation, need to confirm if the axle shaft splines are the same.



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turoc
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Re: VW MK2 front CV Axle options
April 03, 2016 09:17PM
Quote
ElectroTech
Was reading back in some older threads and Derek Bottles had his hubs resplined to work with the DSS axles. Their hubs a built light apparently and wouldn't stand up to rally use.

Pretty sure Derek had his hubs resplined to use 930 CV's.



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Pete
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Re: VW MK2 front CV Axle options
April 03, 2016 09:36PM
double post



Pete Remner
Cleveland, Ohio

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1978
Silence is golden, but duct tape is silver.



Edited 1 time(s). Last edit at 04/03/2016 09:39PM by Pete.
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Pete
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Re: VW MK2 front CV Axle options
April 03, 2016 09:38PM
What generation 80 had the big stepped bearings? I never took a measurement when I did bearings in the Quantum but they are definitely not stepped, and I was fairly sure that they use the same bearing housing as other B2 chassis cars.



Pete Remner
Cleveland, Ohio

1984 RX-7 (rallycross thing)
1978
Silence is golden, but duct tape is silver.
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ElectroTech
Steve Wheeler
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Re: VW MK2 front CV Axle options
April 03, 2016 09:42PM
Seems like this is where he wound up after many different attempts.



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Josh Wimpey
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Re: VW MK2 front CV Axle options
April 04, 2016 09:57AM
Quote
Pete
What generation 80 had the big stepped bearings? I never took a measurement when I did bearings in the Quantum but they are definitely not stepped, and I was fairly sure that they use the same bearing housing as other B2 chassis cars.

All Audi 80s used the stepped bearings. Audi 90 rears use the same hub and bearing (fronts are different)

Never had to change one on my Quantum but they do not cross reference. Quantums also use CVs with nuts just like mk2 & mk3 cars not bolts like the Audi 80s.



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Josh Wimpey
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Re: VW MK2 front CV Axle options
April 04, 2016 10:00AM
Sounds like Derek went the long way around to ending up with VR6-style outers up front





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ElectroTech
Steve Wheeler
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Re: VW MK2 front CV Axle options
April 04, 2016 12:16PM
I like the Audi 80 bolted style idea. Way faster swaps if needed with not having to drop the LCA to get the shaft out of the hub. Shouldn't take much to bore and broach the stock hubs so long as there is enough meat left.



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Pete
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Re: VW MK2 front CV Axle options
April 04, 2016 12:22PM
Quote
Josh Wimpey
Quote
Pete
What generation 80 had the big stepped bearings? I never took a measurement when I did bearings in the Quantum but they are definitely not stepped, and I was fairly sure that they use the same bearing housing as other B2 chassis cars.

All Audi 80s used the stepped bearings. Audi 90 rears use the same hub and bearing (fronts are different)

Never had to change one on my Quantum but they do not cross reference. Quantums also use CVs with nuts just like mk2 & mk3 cars not bolts like the Audi 80s.

So when you say "80" you mean US market 80 and not including the 4000, right? So then that makes sense in my mind now.

I thought the stepped bearings were only on 5 lug models! Good to know.



Pete Remner
Cleveland, Ohio

1984 RX-7 (rallycross thing)
1978
Silence is golden, but duct tape is silver.
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Josh Wimpey
Josh Wimpey
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Re: VW MK2 front CV Axle options
April 04, 2016 12:49PM
Quote
Pete
So when you say "80" you mean US market 80 and not including the 4000, right? So then that makes sense in my mind now.

I thought the stepped bearings were only on 5 lug models! Good to know.

and 4x108mm models apparently.



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http://www.facebook.com/home.php?#/pages/Quantum-Rally-Sport/281129179600?ref=nf
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Josh Wimpey
Josh Wimpey
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Re: VW MK2 front CV Axle options
April 04, 2016 12:52PM
Quote
ElectroTech
I like the Audi 80 bolted style idea. Way faster swaps if needed with not having to drop the LCA to get the shaft out of the hub. Shouldn't take much to bore and broach the stock hubs so long as there is enough meat left.

Should be plenty of meat. The Audi 80 is 25mm diameter at the splines with a hub that presses into a 39/41mm ID bearing. The mk2 bearings are 40mm ID and the same width (37mm) so the hub should still have plenty of meat once machined down.

Now if someone could confirm that the Audi 80 outer CV will fit on mk2 (and mk3 4cyl) shafts. smileys with beer



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