daddyfixit

it happens after driving a few miles? try replacing the osf flexy hose itself, I have replaced hoses on a corsa van that had brakes sticking on....turned out to be the hoses breaking up inside and preventing fluid pressure from dropping---keeping the front brakes binding.

they are a good workhorse, and their replacements are crap............ ark it up, save up and hold onto it until you can afford the repairs... I would wait till Tuesday morning and then scour all local garages/friends/mates/etc to find the cheapest price. mines on 176k, mk2 like yours and I will use/repair it until I run out of faith in it ??

if the splines on the shaft had gone, it wouldn't drive at all. I replaced mine a few months ago with a j&r one (takes about 2 hours on a ramp after getting undershield off)) I think its a slipping clutch from what you described; drive about 30mph, change down a gear and try to accelerate hard-----if engine revs increase but road speed doesn't, then its a slipping clutch. if the flywheels breaking up, there are large springs that are inside the flywheel, when they are worn/broken/weak---the flywheel rattles on tickover speed---until you press the clutch pedal slightly. for either repair the gearbox is coming out, so clutch and flywheel would be changed at the same time (cost effective) and make sure the concentric slave cylinder gets done as well (seen one pop 2 days after clutch repair---taxi driver refused to pay extra for it, then he had to pay full price all over again and pay extra for cylinder as well).

noises -----sounds like flywheel has gone to met its maker ?? plus a clutch slipping again if so, its gearbox out and clutch off again

you will have broken wires in the drivers door gaiter, they always break; allow a couple of hours at least after reading the pinned posts on how to repair them. never re-join the wires, instead extend them an inch or two so they have more free travel---less chance of it happening again. always solder and use heat-shrink tubing on loom repairs.

update to this long-running thread I sent two pics from barnstormer to Lee at j&r drive shafts in brum, 2 days later part number ds523 arrived. on the Saturday morning at 07.30 I stripped car down in my mates garage to find it was indeed the wrong one !! re-built car after ringing J&R who open 7 days a week according to flyer that came with the shaft..........they are shut !! I rang lee back on the Monday, turns out they had mis-packed shaft......he said correct one would be there next day and courier would take the other shaft back....he gave me a vw part number for a sharan/audi mounting bracket, shaft would only fit if I got one......local breakers had one! last Saturday I stripped the car down again; fitted new driveshaft oil seal from ford (£8.10) , and the stub & intermediate shaft, all parts nuts/bolts/washers/springs in the kit were 100% correct !!! shaft number ds466 costs £70.00 delivered with a 3 year warranty..... ok its only been on a week but i no longer have that feeling that the splines are holding on by sheer good luck ! I will be keeping an eye on it as I have free access to a 2 poster ramp and will keep any other 90bhp-anu engine galaxy owners updated.

1. centre punch a dot in dead centre of broken stud 2. go to toolstation for some cobalt drill bits (3,4,5,6,7,8,9 mm---I bought 2 of each as I was on a lonely shopping day !! ) 3. drill a pilot hole with the smallest drill bit 4. drill the hole again with a larger drill bit 5. keep going until there is very little left of the stud DONT BREAK THROUGH THE SIDES OR THREADS GET DAMAGED 6. Try the BIGGEST extractor that you have 7. or if you have a set of 1/2 drive torx sockets ----hammer the biggest one possible into the hole and use rachet or breaker bar to loosen it

just replace the boots only---drop shafts off car at gearbox flanges I was on phone ordering the offside inner shaft for mine yesterday from J&R in Birmingham, it arrived today with a special offers leaflet-----galaxy full drive shafts are only £35 delivered !!!!

uk laws are that the offside fog light has to work to pass mot test, but some vehicle manufacturers do have the dummy one on the nearside so car looks ok from rear. I assume the anti-roll bar drop link is worn, don't buy a cheap one as they don't last 5 minutes. rack gaiter; remove track rod end----counting how many turns it comes off, ( depending on size of gaiter you may have to remove lock nut as well ) new gaiter will be held on with cable ties, refit track rod end counting it back on same amount of turns it came off. new front number plate, pair of new tyres and 3 bulbs ??? a mornings work as long as the rain hold off

brake light switch is faulty then............

alternator pulley will cause stupid noises on full lock; on a lock it absorbs pulses caused by power steering pump--but when it fails/locks up it cant so the belt squeals and groans. mine went with no warning the day it had a leaking steering rack fitted....I thought it was the power steering pump low on fluid. mine has done 173k so I can live with that !!! genuine item (valeo) from c.e.s Liverpool was £40 but special tool needed to remove the pulley once you have taken the drive belt off.

barnstormer, can you email me that photo please ? I want to send that to j&r in the morning ? I have just sent a message and will send my email to you.

had it on the lift again this afternoon; theres about 3mm of free play in the 2 shafts as you twist the, plus a loud squeak and the dreaded rusty marks around shaft/gearbox flange. Its obvious its the stub/intermediate that's needed---but I am not paying stupid ford prices !! I will speak to j&r on Monday as they say that although its not listed on the website , they do a shaft for the ANU motors. I cant see why the anu cars have a large alloy " cradle" around the driveshaft to act as support bearing holder ? all the other cars have a flat metal plate with the support bearing attached to it..... now I wonder if I leave off the cradle and use the other type, will it be too short or too long ??? hoping j&r have an answer ???

mines an x reg mk2---90 hp anu engined; I have the dreaded clang on overrun/acceleration, checked today and the inner shaft is worn where it goes into the gearbox stub. mine also has a cage surrounding the shaft, after reading pos on here i can see its going to be fun getting a new one ??? motomax in Poland do not make a replacement but much nearer home ,j&r driveshafts in Birmingham do !!! I spoke to a lad there this afternoon called dave; he took my reg number and engine code and he says he does do a replacement ---so when I get back from my hols/get paid I will be getting one off him and will report back on here when i've fitted it.

steering rack burst on mine last Saturday.....nearside pouring oil out. got an exchange rack fitted, was advised that alternator freewheel pulley was goosed.................caused noises/judders on full lock, this was masked by the p.a.s. pump being noisy when fluid was lost. no warning/odd noises---just packed in ! fitted new one on Monday and now spending rest of my hols sorting out niggles/rattles and a full service.

got the rack fitted Monday; dropped it at mates garage at 08.00, he rang me at work to say he was awaiting delivery.....then rang 2 hours later to say it was done !! I put in on 4 wheel aligner this afternoon and found tracking spot on----he had used old-fashioned Dunlop gauges !! then found out the weird noise on full lock is the alternator free-wheeling pulley.....so that's being done Monday on my hols.

i am more annoyed that it went without warning ! was on way home from mates garage when she rang to say somethings wrong-----if it had happened Friday then I could have done it myself on Saturday ! we are both in work tomorrow and kids still at school, so we need it asap---hence dropping it off at mates garage in morning then seeing what exchange sh*te racks are available....delco-remy have bought out xl racks (horrendous crap) but until all the factors open in the morning I don't know whats available !! but the cars done 176k, I have had it 10 years so fair enough...lets get it fixed and back home asap. its also due a full service so I will do that on Saturday morning as we are going out as a family on Saturday afternoon so its got to be sorted 100% I will keep the board posted with progress and prices

the mrs called me to say the car makes a groaning noise when cornering---she thinks the brakes are sticking ? I get there to find no fluid in the p.a.s. reservoir. I drove slowly in 6th to keep revs down to my mates garage around the corner. we put in a liter of the green vag fluid and i thought all was well..................till looked at nearside wheel. covered in oil and the rack gaiter split open leaking oil............after 176,00 miles my poor little car has well and truly sh*it its pants !! trying to arrange getting an exchange rack Monday/Tuesday so i can get mobile again as we both need a car for work and kids still at school for a week.....then when its back will spend a week of my hols pampering it as recent financial disasters have meant the 2 cars have took a back seat in the spending money department.

specialist; they will gas/leak test before filling fully-----------after adding uv dye they will leave it running to see where the dye is leaking from using special glasses, after that if its not leaking, it gets vac tested before final fill.

seem to think the last one we got was from eurocarparts in Liverpool ? if so they must stock nationally ??

remove heater control panel disconnect both multi-plugs switch ignition on while its disconnected totally turn ignition off refit the multi-plugs refit the controls try it now

ive had it 10 years, when I first got it I blitzed it with waxoyl....noticed last year that it was bulging under the stonechip on both outriggers. on ramp last week I made the mistake of prodding with screwdriver...........so had to do drivers side there and then, on mot yesterday he noticed other side was gone. original under seal from factory was about1/4" thick in the corners and was a pain to get off where angle grinder couldn't reach.

it wouldn't wear out? but did you ever replace the fuel filter and it comes with new 0-rings in the box? try replacing them .

x-reg mk2 tdi; something to look out for ??? had to repair a 2" hole I found last weekend while car was on ramp getting new exhaust middlebox. were the osf chassis joins the outrigger that leads to the sill---very thick underseal was hiding a mousehole !!! 3" x 3" plate was easy to do & then seam sealed and stone chipped it went for mot today and the nearsides the same !!!! should have scraped the stonechip away last week but didn't...................... same repair and motd again within the hour.

dash, by your right knee