Drive Shaft Failiure

[Coxsey]

Well my second problem with the Galaxy <_< occurd on Saturday just gone......

 

Picked daughter up from swimming in the morning got to a set of traffic lights and went to pull off and all that happend was an expensive sounding grinding noise and no movement.....

 

It turns out that the drive shaft had lost it's splines (Teeth) where it goes into the gear box.

 

Has anyone had this happen to them..... or am I just unlucky....... :(

[Ivor_E_Tower]

Not heard of that happening before, on any car.

<_>

[Coxsey]

Just picked up the car from the garage and had a look at the damaged end of the drive shaft.....

 

The teeth had worn away not snapped off!!!!

 

When they eventually ordered the correct part they asked Ford's if they have many in stock as an indicator of how often this goes wrong... they had almost a hundred instock!!! <_<

 

For information I have a 51 plate TDI registered in Spetember. Apparently there a couple of differant designs of shafts....... Milage was 63500

 

On a good note tho.... they didn't stock any gear boxes........

[Topbloke]

did you ask how many air con units they had <_< :( :D :D :D

[Guest dmc]

Well my second problem with the Galaxy <_< occurd on Saturday just gone......

 

Picked daughter up from swimming in the morning got to a set of traffic lights and went to pull off and all that happend was an expensive sounding grinding noise and no movement.....

 

It turns out that the drive shaft had lost it's splines (Teeth) where it goes into the gear box.

 

Has anyone had this happen to them..... or am I just unlucky....... :(

ive seen this a few times,so your not the only one.

[Guest JonathanK]

Had the same thing 6 weeks ago on my 02 Alhambra with 70k up.

 

 

[Guest Jonderonde]

Just done my 1.9TDI 115 51 plate 57000 miles. Nearly

[finni]

Well my second problem with the Galaxy :blush: occurd on Saturday just gone......

 

Picked daughter up from swimming in the morning got to a set of traffic lights and went to pull off and all that happend was an expensive sounding grinding noise and no movement.....

 

It turns out that the drive shaft had lost it's splines (Teeth) where it goes into the gear box.

 

Has anyone had this happen to them..... or am I just unlucky....... :(

[Bigjeeze]

Finni

 

are you saying this has happened to you?

[GrannyPower]

Hi Coxsey.

 

The same thing happened to my Galaxy about 3 months ago.

 

The teeth on the output piece on the gearbox had stripped leaving me with no drive.

 

After going to a Ford Dealer who recommended a new gearbox, I tried another one.

 

Ended up buying the output flange for about

[Sher]

This is a VERY common fault on 1.9TDis and all owners should be aware of it.

 

Symtom is sloppiness and noise when pushing the accelerator pedal and taking it off.

 

I suspect the bearing on the end away from the splines is not upto the job and allows movement of the shaft so the teeth wear especially if there is slack/ wear in the peculiar (to me) half shaft internal offside universal joint.

 

Even had Ford Mechanics claiming there could be a gearbox fault.

[p10ant]

Hi, This is a common fault, I've replaced 3 in as many months (2 Alhambras and 1 Galaxy). I think its down to being assembled dry in the Factory. When you do replace, make sure you replace the intermediate shaft as well as the stubb shaft , if you check the splines in the intermedate shaft you will find that they will be very sharp/worn making a poor fit in the new stubb shaft, and it won't be long before they fail. Also when assembling the new shaft coat the spline in some Hi Temp grease.

 

Cheers, Paul T.

[tim-spam]

Not heard of that happening before, on any car.

 

This is a VERY common fault on 1.9TDis

I have to say that I agree with Ivor on this one. I too have never heard of this problem before (except here, of course). It appears to have affected only a few people on this forum out of the many thousands of members. Certainly, there are many cars that have racked up very high mileages with no failures in this area. However, should my car ever develop any significant slack in its drivetrain, I shall obviously check the splines on the intermediate shaft.

[Sher]

It may be specific to vehicles manufactered around 2002. Since the fault only seems to appear after 60,000 miles its outside warranty.

 

(1) My friend, a Ford Mechanic warned me about this. Seems Ford specify a particular grease for this part.

 

(2) My local non Ford parts supplier did not have the replacement shaft in his catalogues.

When he contacted the manufacturer/ re-manufacturer for half shafts http://www.shaftec.co.uk/ about the correct part, they also told him about this other problem. He in turn told me, but I already knew.

 

After fixing, in 2 stages , half shaft 1st, then the output shaft from the gearbox the improvement was very marked at each stage.

 

Seems to drive like new. For some reason the gearchange seems better as well!!!!!

[bilbo]

Hi, This is a common fault, I've replaced 3 in as many months (2 Alhambras and 1 Galaxy). I think its down to being assembled dry in the Factory. When you do replace, make sure you replace the intermediate shaft as well as the stubb shaft , if you check the splines in the intermedate shaft you will find that they will be very sharp/worn making a poor fit in the new stubb shaft, and it won't be long before they fail. Also when assembling the new shaft coat the spline in some Hi Temp grease.

 

Cheers, Paul T.

 

new member

 

hi pauy could you please help i have a 1.9 tdi 130 could this problem be related to geting wheel wobble

change wheel bearing and nearside drive shaft and still cant get rid off the wobble i to come from

from grangemouth

and would like abit off advice

[Rusty Nail]

Hi there all.

I have just had the intermediate drive shaft / stub shaft failure on my 2002 TDi Galaxy (103K miles).

Same scenario as many, pulling away from a junction, there was a bang followed by a horrible mechanical grating noise and no drive.

On dissmantling the faulty components (only takes about 30 mins) it appears that the failure may have been accelerated or contributed to by the failure of a seal.

It looks as though there should have been a rubber seal between the stub shaft assembly collar and the intermediate shaft. With this seal gone, water etc can get in and corrode the splines. This along with general wear and tear of use/abuse over its life leads to the failure.

 

I have contacted my local Ford dealer who couldn't find either item on thier high tech system, then tried a parts supplier - no luck there either, before finding the parts readily available from VW. They had no history of these parts failing but could not guarantee this as the just had a new computer system and all thier records had been lost. A mechanic at the ford garage commented that he had only just replaced the same items (pattern parts supplied as Ford on back order) last week on a 2002 model also.

 

I shall continue to search for the parts but would be greatfull if anyone knows anywhere I could get them

 

Thank you for your time to read this

 

Russ

[Sher]

Its not easy to pin point on the Ford Diags.

Not as far as I know available except from the agents!

A standard often replaced part on this model year I think

 

This is off the Box mine am in:-

 

F/C 1140358 EJE/SHAFT ASSY

 

Part Number 1M213B428AA A.T.4F3

 

I have a 2002 115bhp 1.9TDi Galaxy Ghia

 

This part may not be the only problem. The outer section of this assembly, the half shaft may be required as well. That can be sourced elsewhere at a good saving.

[Bigjeeze]

http://www.fordgalaxy.org.uk/ford/index.ph...lange&st=30

 

 

Have a look here - I had this problem some while ago!!

[Rusty Nail]

Hi all

 

Just an update on the saga.

 

I managed to get hold of a new stub shaft and intermediate shaft from Ford for

[Sher]

So I wasn't dreaming when I mentioned in a previous posting that the gearchange/gearbox performance seemed to improve after I changed the same part.

 

Do any of our real experts have any suggestions as to why?

 

As regards price for this part in Spain I paid 180

[AD90]

Hi All,

 

No apologies for bumping this item.

 

Just had a failure on our 51 plate, 61,000 mile Alhambra 115PD.

 

The Part Numbers for a 51 plate 115PD: 02N409344E & 02N409345 and stung me

[Ginettamad]

One of my mates told me to check this issue as soon as I got my Gal as he has replaced several shafts with worn splines.

He also claimed its due to the tight factory assembling the joints dry ie without any grease! Stupid as it has to slide metal to metal in use so no wonder they fail. The factory should be footing the bills really. I plan to remove mine at some point and grease it up! My car has done 96k and its a 110 TDI?

The only problem is that no one here has stated which side the problem occurs drivers or nearside shaft?

I've still got plenty of other jobs to do first however only had it a few weeks.

H

[AD90]

The problem can only occur at the Dirver Side (RHD) it where the intermediate shaft connects to the stub shaft sticking out of the Diff(Gearbox). The other side does not have an intermediate shaft.

 

AD90

[gregers]

and how will you know when its starting to fail?

[AD90]

Some of the posts suggest that gear change will get worse and you will notice the slop on the transmission. But my daily drive is an 18 year old Landrover, so I probably didn't notice anything :-)

 

Until shooting across the lights at a busy intersection, with the kids in the car :-(

 

I am seriously hacked off that neither Ford, VW or Seat have had the decency to own up and issue a recall.

 

AD90