I normally don't do this, but I'm taking a private reply to me and
putting it on the list, sans name.  

So far, I've had 3 responses to my query.  One person says
it's not a problem, and that someone put grease in the wrong spot, one 
that the hole is not supposed to be there and that he took a day to have
the whole thing replaced when he saw the same symptoms. And the last, this
one, tells me that that it's potentially fatal.
I could use some help.  Read on.

>Ian Frechette wrote:
>> 
>> It seems a bit odd though.  Is that whole boot packed with grease, or
>> is this a bigger, problem and the hole is supposed to be there, but
>> the grease is not.
>
>There isn't supposed to be a hole, and the boot isn't packed with 
>grease.  The CV joint itself has a lot of grease around it.  The
>centrifugal force probably threw the grease out once a hole opened
>up.  Whatever you do, don't drive it until the CV joint is flushed
>and re-packed, and the boot repaired.  Your checkbook will thank
>me later.....

There's only a couple problems I see with that theory.  The hole that I'm 
talking about is at the small end of the boot.  I could understand it 
flying out if it were up near the actual CV joint near the tranny at the 
big end, but it's out in the very last "bump" and what's even more odd is 
.. well let me draw a picture.   (I've got a real picture too.  URL below)

   .-hole    __
   v    _   /  \___
   _   / \_/    |
__/.\ /        _|
---------------|| tranny
---------------|| CV joint
^    ^
`- X `-- Y 

This is the top half of a cross section drawing.

Note that the hole is out at the end furthest from the actual CV joint.

I looked at it again this evening and what struck my eye is that 
the rubber at both X and Y is touching the shaft.  That would imply
that the last chamber where the hole is is isolated from most of
the rest of the boot.  The only way grease could get out there is if
the entire boot were totally stuffed with grease, which doesn't make sense,
or someone just pumped that last chamber full of grease through the hole
by mistake.   I'm thinking it's the latter, and someone else has
suggested as much.   

Ok, here's the real picture I just took.
http://rintintin.colorado.edu/~frechett/stuff/boot1.jpg
See the hole?  It's perfectly round, well formed.  It's not a tear or
a crack.   The picture makes it look slightly ragged.  That's a trick of
the light.  It's smooth and looks to me like it's meant to be there.

Another thing I noticed.  The right side drive shaft appears to have
a sleeve over it.  The diameter of the left shaft is 1 1/16", and is
solid.  The diameter of the right side sleeve is 1 5/8" and is hollow.   
This is the side we're looking at, but from the front of the car.  I'm 
positive there's a solid shaft inside it, because look at the first "dip" 
to the right of the "bump" where the hole is.  It's smaller diameter than 
the 1 5/8" sleeve to the left where the clamp is.  In fact, it's 
1 1/4" in diameter, which is about right to account for the thickness
of the rubber in the boot.

I think I can conclude that the grease didn't come from the inner CV joint.
It was either injected through the hole, or it came from inside the hollow
housing around the right side drive shaft.  I looked at the other end of the
sleeve
http://rintintin.colorado.edu/~frechett/stuff/boot3.jpg
and it is clearly sealed tight as it shrinks to the same size as the
drive shaft and is clamped before the outter CV joint.  Therefore I can 
see no reason why there's be grease inside there.  In fact, I can see no 
reason why the hollow sleeve should exist at all.   Anyone have a Bentley 
handy?    What's the sleeve for?

I think the hole is to drain water that might get into the hollow sleeve
somehow.

Also, if someone has a couple minutes, I'd like to prove that the hole is 
supposed to be there.  Just takes rolling the car back in 1/4 turn 
increments and looking in there with a flashlight from the top, down past
the headers.

BTw, this is the mess I first saw that caused me so much initial concern.
http://rintintin.colorado.edu/~frechett/stuff/boot2.jpg
Yuck.  And yes, I know the grease came from the hole in question.

Any more info would be appreciated.

	ian

P.S. Andy if this whole thing is ever resolved, feel free to use the
   pictures if you want em.
--
For info on: how to subscribe & unsubscribe, the list's tech/how-to
    library, etc.  see:   

Ian,

    I recently went through a similar problem with my 95 GTIVR6, but it was
the outer CV boot.  There was just a small pinhole, barely visible to the
naked eye.  But within 50 miles, my fenderwell, wheel, and suspension were
covered with that thick black grease.  Think about how fast that driveshaft
is spinning at 80 mph and you'll understand how grease could be ejected from
that hole.  I'd get it replaced ASAP so there is no wear on the CV joint
from dirt contamination and lack of grease.  Don replaced my CV boot in
about 45 minutes.  It's not too bad with the proper tools.  Good luck!

Later,
Greg
-----Original Message-----
From: Ian Frechette <frechettrintintin.Colorado>
To: gti-vr6dev.tivoli <gti-vr6dev.tivoli>
Date: Monday, October 19, 1998 2:43 AM
Subject: Re: [gti-vr6] inner CV joint


>
>I normally don't do this, but I'm taking a private reply to me and
>putting it on the list, sans name.
>
>So far, I've had 3 responses to my query.  One person says
[...] 101 lines deleted