Front Drive Shaft Update

[pmatusov]

Something like the C clip used on early Chevy 10 bolt or early Toyota diffs that held the drive axles and bearings in the housing at the diff would be a solution for the circlip. There is a lot more force put on c clip from an axle then a drive shaft would ever produce.

It is probably the first plausible idea in this thread!
However... The clip used in the current (nearly all) CV joint is installed on the shaft before mating it with the joint, so the 10-bolt-style C-clip cannot be installed the same way. It is not clear if it can be installed even if the CV joint's "backside" is accessible.

All in all, c-clip failures are baffling here. The driveshaft should never experience any significant compressing or extending force. Either the groove is too shallow or the clip was never seated properly.

 

[acky]

surely its a case of boot fails, grease exits the chat, heat and metal on metal fatigue causes the c-clip to depart

 

[globalgregors]

I have just spoken to the supplier of the Eibach (grey standard) springs that I have fitted and they have spoken to Ineos with regard to the lift that these springs create, there would be no warranty issue if the clip or CV fails. These springs are the same size as the originals but the lift comes from there extra strength, less sag. I fitted these for load and towing weight, so far so good.
The supplier stated that the vehicles especially the QM are certain to have GVM upgrades and isn't that what Ineos Grenadier is about.

We have >60,000kms of often hard use on a pre-production set of those springs with no sign of issues. Touch wood.

I’m harbouring a theory that the additional weight of the diesel + roo bar + winch + expedition fit out alleviates the problem by reducing the range of travel in practical terms. Well, to be clear not reducing the range obviously but shifting the static point versus bump/droop min-max. Not an engineer however so one defers to the room on that.

 

[pmatusov]

surely its a case of boot fails, grease exits the chat, heat and metal on metal fatigue causes the c-clip to depart

There's a perfect counter-example to your explanation in this thread.

 

[Dokatd]

Keep in mind there are nearly if not zero diff side clip failures. So far testing shows the CV does not get excessively hot except when the grease leaves the chat. It's the binding of the joint that causes both boot and clip failure.