Quote Originally Posted by strat24v View Post
So in effect, the only thing that is limiting the inner races, shaft and balls from exiting sideways are the rubber boots? I'd look at some sort of soft compressible thing in the joint. Didn't they used to use half a tennis ball or something?
If the shafts are the correct length then balls should not be able to reach the point where the balls can fall out of the CV body, the inner flange will prevent the shaft migrating too far inwards and the out stub shaft would prevent it moving too far outwards. If the shaft is too short then there could be cause for concern. Hawk & LB don't have this issue because the outer CV's only rotate, they do not plunge so it is not possible for the shafts to tramp side to side. There is nothing wrong with a double plunge shaft as plenty of cars use them but the length of the shaft is key to its success/reliability.