Hi,
Sorry, I saw your Q on your last thread last night but never answered.
Did you dismantle the CV's? i.e. Did you get to the stage where you have the inner spider, outer ring, cage and six balls, all seperate?
If you did then you have simply re-assembled it the wrong way 'round. The grooves (that the balls run in) don't run parallel if you look at them in the inner spider or the outer ring. Any two grooves will be closer at one side than at the other. If you re-assemble it in one orientation then the joint will be effectively jammed and won't flex.
If you have done this then you need to dismantle the joint (can be tricky if it really is jammed), and rotate it such that the grooves are in the other alignment (i.e. move them one sixth of a turn in relation to each other). I seem to remember that the correct orientation is such that, if viewed from an end, a narrow gap between grooves on the inner spider is aligned with a wider gap between grooves on the outer ring (but I could be wrong.) You could however easily check this with a known-correct CV joint; i.e. one that you haven't dismantled.
From memory, the orientation of the inner spider and outer ring doesn't matter in terms of which end points in which direction, although (again) you could check this in reference to any other known-good CV joint (or even a picture).
Two other things; 1. Slather the whole thing in proper CV grease while reassembling (sounds like you are doing this already), and 2. If you aren't dismantling the joints then it is worth swapping them 'round so that they drive on the 'other side' when re-attached as this will increase the life of the joints. The easiest way of doing this is to leave the joints on the driveshafts and swap the shafts from one side to the other. (This sounds odd but makes sense if you think about it.)
Keep us posted with how you get on. If you are still stuck I can see if I have an old CV joint kicking around in my workshop which I can take some photos of.
Oli.
