Outer Limits 4x4 Board

Just thinking about swapping the bigger 8" diff for my 7.25" - are the CVs different sizes?

Short answer yes they are different size.
But only the the outer part of the inner CV joints are smaller every thing else is the same size ie inner section of inner joint, shafts and outer joint are the same.
There are some larger joints fitted to some 2.8 tdi and 3.5 lt they have 90 stamped into them along with some other letters smaller ones (standard) size have 85 stamped into them along with some letters.

Regards Glenn

glenn_c wrote: But only the the outer part of the inner CV joints are smaller every thing else is the same size ie inner section of inner joint, shafts and outer joint are the same.

Sorry to hijack, but are you saying that in the larger diffs the outer "housing" of the inner joint is bigger? Longer? Just the reason i ask is that i changed my CV's when i did the balljoint flip and the LH CV fouls the shaft on the inner joint housing when at full droop and pushes the diff in slightly when rotating. I'm just wondering if the supplier has supplied me with the larger cv on that side causing this issue. It's been bugging me for a while.

The smaller diffs have smaller spines in the diff but everything else is the same.
Then just to confuse things the larger diffs have two dirrect size CV's, spines into diff and the hub are the same but the ball (outer) of the CV's is bigger by 5mm and the shaft is about 3 mm bigger on the ones with nubers 90 and some letters stamped into the joint than the standard ones with the numbers 85 and some letters stamped into them.

But be careful with the ball joint flip I ran a ball joint flip for two years but I kept breaking left hand CV's (some in the spine going in the diff)
due to binding, so I went back to standard and no more broken CV's.

Regards Glenn

Yes there certainly are differences alright.
I've eyeballed 5 different types of Pajero CV's the variations I've seen are in ball size, spline count, length and mounting flanges.
Early small diff CV's are 28mm diameter but 25 spline.
Sometime in the late 80's this was standardised to 28 spline (same as the larger 8" front diff).
Some are different lengths (between large & small diffs and auto vs manual) early small diffs had different mounting flanges.
As said above 3.5 & 2.8TDI's have subtely larger CV's than 3.0 models.
Remember the Gen 2 has about a 1.5" wider front track than a Gen 1 so overall lengths will differ.