Corse I CV joints

[hollytree]

Is one cv plunging to its limit and a ball popping part way out? What are you using to limit the plunge?

There are no limits on the shafts to stop excess plunge. The shaft goes in through the gaiter, through the bearing and then a circlip goes on to stop it all falling out.
This is the same both ends of the driveshafts, both the inner and out CVs.
I have checked and now limited the droop, so that at full extension there is still side-to -side movement, so that the circlip is not trying to pull on the cages.
I have also jacked up the car and spun the wheels when at full droop when holding and pushing the driveshafts fully towards the gearbox, and fully towards the hub to see if any noise,contact etc. All negative.