My front right inner CV joint is toast - moves in and out limited by the intact boot. This is a manual transmission, so parts availability seems to be limited.
Is there a rebuild kit for this or do I need to get a new axle assembly (these are $$$$)? Other alternate is to go to the scrap yard/part locator.
Any suggestions?

 

Ar you actually having problems with the joint? Is this something that you happened to notice while checking other things on the car?

The inner joint is a plunge joint. This means that is is the one that moves in and out as the suspension moves. So moving in and out is normal. The out movement is normally mechanically limited by something to stop the tripod from coming out of the joint.

 

Well yes on the discovery while replacing the struts and I can see the need for moving in and out. The joint kind of popped out. It is a bit loose on the twisting and I have a clunk when the clutch is let out. I was thinking this might the source of the clunking. Well, struts will be finished tomorrow and I was skeptical of putting it back together if the axle was an issue,

Is this a repairable joint that I could work on in the future?

 

what year is your car? A few options 1) search on eBay. there are rebuilt axles available for most years from what I can see 2) Search yards using cart-parts.com 3) contact Erie VoVo - they specialize in used Volvo parts - they are in Whitesboro, NY - just east of Syracuse so shipping or driving over wouldn't be that bad. 4) by a replacement - try FCP Euro, EEuroparts and if not available, Tasca Parts has the best Genuine Volvo pricing (ship out of Rhode Island).

 

car is a 2006 V70 non-turbo manual FWD

 

Does anyone have a pic of what is inside this joint? I hesitate to pull apart without knowing as it is a daily driver and need to schedule around college breaks.

 

CV joints are pretty similar so any picture you Google will suffice.
I'm pretty sure a pair of snap ring pliers is the only "special tool" you'd need.
Given the strong construction of the inner boot (not flimsy rubber) a Volvo replacement makes some good sense.
See if there's a shaft shop near you.
There is one near me.
I'd call ahead to make sure they had my CV joint in stock and then just drop it off or arrange to wait for the repair if they weren't too busy.