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I know what your saying and that is not entirely the case here. at full droop my axles are at 36 degrees now at ride height 26 degrees and just went and checked with it sitting in the garage w/o pass. I gave up 6" of gc ( which is 18" of gc with the wife and I sitting in the rail) to smooth up the ride and with the 2.5 airs It works well and really like the ride. they soak it up good but do need prob 20 cc's of oil to complete it and since i forgot my shock oil I didn't get to tune them. my fronts need re-valved, faster compression and slower on rebound.the little pressure needed to tq lock those splines is concerning and the axle pop once they slip under load is far more than concerning but it seems that 3/8" available plunge is the magic # or less to stop the axle pop noise which sounds like a hammer btw. I had no issues with boots just used he wrong clamps on the boots and those two boots slung grease, easy fix and actually one did right off the bat then I got it stopped 3 days later the other started. carl is right move it 1" and they slip easily! my intention was to keep the travel and still get it in the trailer with paddles on and I did just that with room to spare. now if I continue with cv's I will change axle length from 28" to probably 32" and relieve a little more angle w/o giving up gc at full droop. probably re-vamp my carriers to utilize all of my 4.5" back space. they both have pro's and cons but I still pre-fer uj's after experiencing cv's again after soo many years. only had issues with uj's once out of all my rails and that was because they were the lowest quality from drive shaft super store and couldn't handle my 3.8 v-6 . none of the rockford's ever had issues!! they don't have the play or the mess but limited to 30* or atleast I would never go beyond that and i believe equal in weight to these cv's I have + less mess!! just my opinion after 10 years of uj's. just letting others know what I have experienced first hand now but still in the experimental stage. you are correct there isn't a boot that will handle over 40* nor have a long life over at a constant over 30* and neither of us need such a thing. my high angle boots are just fine, I used a retaining flange that cover the edge of the bolts and carl didn't so you can clearly see where the boot made contact with the bolt heads and wore through till it ripped. it was surprising that no one down there sold high angle boots for 930's!! simple and easy fix for carl as well. I know the higher the angle the higher the heat produced and that kills cv's as well and with uj's the higher the angle you don't get that heat but the weaker the uj's were the cv maintains strength. both have pro's and con's so it come down to the user. i do now remember why I went uj's!!
WHat carl experienced is totally normal. You,on the other hand, have a deflection/bind/spline mismatch issue (any or all ) ,IMO,that is creating the abnormal torque"lock" and high heat that you experienced. Cv's just do not/will not act like that when not put in a bind or running massive HP. Correct that and the superior cv's will serve you quite well. My cv's are comfortably warm to touch even after a long run. My car is much heavier than yours and boosted also. Why are mine not experiencing your issues? No binding. I'm betting the "lock" you are having issues with is due to poorly matched splines creating localized load concentrations. This will happen when sourcing axles for cv's. Remember that not all splines are alike since there is no universal standard for splines. Each manufacturer is free to use their own specification since splines are dependent on shaft theoretical OD and ,again,there is no universal standard to adhere to.
the other diff fabbr is your open diff and plunging axles!ok since you don't have clips on both sides of the cv's , with plunging axles and open diff, w/o tq lock on the splines what keeps them from sliding down into the cups? not trying to promote one or the other just trying to wrap my head around this. i can say with all the slop in the cv balls and splines they help a live rear end turn sharper on dirt or sand but not pavement yet. although the axle pop is gone I can still feel a bind when on pavement and I am surprised with all that slop in them they don't break easier. I will have to play around with clocking them and I wonder if they need to be aligned like a uj side to side as well as end for end? don't know anyone with experience with this app, live rear with np 930's.
lol we will see
My axles still lock a bit if just sitting still and trans is in gear-just normal and has no effect when rolling just as yours . the axle can't slide into the cup.It hangs from the top/inner clip and since the star doesn't plunge that's all that's needed. The bottom/outer clip is actually unnecessary but I put it in anyway. No need for clocking a cv. Of course you feel them bind with a locked rear drive just as you do with a UJ. A cv does not/cannot overcome that- sloppy or not.