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There any chance the ring/washer on the back of the inner bearing is on backwards? It has a depression on one side but not the other.

It can be seen in this picture. It is the gold/brass colored ring pushed up against the cv.
http://img641.imageshack.us/img641/4852/1010293k.jpg


That is a great observation. <img src="/forums/images/graemlins/kewl.gif" alt="" /> That is the first thing I am going to look for. I remember trying to remember which way it was supposed to go. The crazy thing is that ring is not in any exploded view. The photos here are awesome.