Engine Stabiliser

[GrannyPower]

Hi everyone, My 2002 tdi 115 did exactly the same thing a few weeks ago, the gearbox output flange completlely rounded off leaving me with no drive, only symptom was a occasional knocking sound when lifting off throttle at low speeds.

[buford_t_justice]

 

To use a colloquial saying - "Bollocks" there is no way this is a normal wear & tear item - I have never ever heard of this kind of failure anywhere else - It's only the fact that I have done 100K plus miles that makes me feel slightly better about it. Typical blase garage shite!! :blink:

 

Not that I'm angry at all :)

 

 

I kinda said that to him as well. He didn't seem too impressed. Claimed it could have happened for all sorts of reasons!!

[Bigjeeze]

 

To use a colloquial saying - "Bollocks" there is no way this is a normal wear & tear item - I have never ever heard of this kind of failure anywhere else - It's only the fact that I have done 100K plus miles that makes me feel slightly better about it. Typical blase garage shite!! :ph34r:

 

Not that I'm angry at all :D

 

 

I kinda said that to him as well. He didn't seem too impressed. Claimed it could have happened for all sorts of reasons!!

 

 

 

 

 

Its probably not worth pursuing - but it would be interesting to hear his reasons! Its easy to talk but lets see the hard facts!! - Its a design/manufacturing defect - period!!

[Sher]

Perhaps a better name for this topic should be

 

"Off side Half shaft problem combined with worn splines on output shaft from Differential"

 

A common well known problem with 1.9Tdi from around 2002, or maybe before at around 60,000 miles.

On the offside/ drivers side.

 

ALL 1.9Tdi Owners and perhaps others should watch/listen for this.

 

Symptoms:-

 

(1). In intermediate gears (3/4) accelerate and back off and listen for clunking noises. Perhaps noises on changing gears.

 

I even had similar noises when depressing clutch pedal and moving between gears without raising the clutch pedal.

One Ford mechanic suggested that the synchromesh inside the box was at fault.

 

(2) Wheels off the floor, undertray removed. Rotating offside wheel back and forth gave a clicking/clunking noise from the inner unlikely looking UJ.

Once stripped proved to be worn as one of the 3 bearings inside the housing fell off.

 

(3) Before stripping down I examined the movement available along the shaft connecting the Inner UJ through a bearing to the diffential unit at the lower end of what I presume is the gearbox. This seemed to contribute more than half to the slackness in the driveshaft system on the drivers side.

 

This shaft is easy to remove and proved to have rather sharp edges on the Male Splines. The edges of Female splines inside the differential unit had edges but not sharp. With nothing to compare with directly I could only assume the mail splines on the output shaft linking to the Half shaft (better name One third shaft) was also worn.

The bearing which is attached to it seemed to have more movement than I would expected.

 

Repair:-

 

(1) Outer Half shaft replacement gave a wonderful improvement in driveability (the inside transfer shaft was not available at once).

 

Hadly any noise as mentioned in (1) above.

Gear change noise much improved if not all gone.

 

(2) Two days later the subsequent replacement of the inside shaft allowed the comparison of the new with the Old.

Much worn Male splines on the old shaft. ( Grease was not dry !!!)

 

The whole problem may be linked together with the worn bearing on the shaft allowing the splines to wear and in turn putting pressure on the 3 bearing CV joint inside the steel boot.

 

Whatever, this is not a fair wear and tear problem.

The passenger side shaft is ever so slightly noisy but has no slack in it when the tyre wheel is moved back and forth. I presume for the moment this will do.

 

Definately a Materials or design fault.

 

Total cost including labour about

[t1Star]

Hi All,

 

I recently purchased an Alhambra 1.9TDI. The car has done 70k miles.

 

There was a clicking noise and this 'completely' went away with the drop linkages being replaced.

 

Then a couple of thousand miles later on the M1 on a saturday morning at 70mph, heard a clunk I thought I went over some debris, then a GRINDING noise I thought I heard a burst tyre. But NO the CV had dropped away, the drive shaft had come apart from the intermediate shaft. Cracking the engine oil sump and the turbo pipe at the bottom.

 

Relayed back. Had these parts replaced, Intermediate shaft new, drive shaft reconditioned and turbo pipe etc. Did not have the female flange in the gear box changed. The splines on the old intermediate shaft weren't in a bad shape.

 

Since then, this was about 2 weeks ago. There is clicking sound whenever I come off the accelerator or go into reverse. :blink:

 

I am now still concerned and thinking seriously -- should I go back to smaller car again.

 

Any advice or comment would be greatly appreciated.

[Bigjeeze]

I would replace the female end as well - I originally wasn't going to change mine but realised that for an extra

[TimsBamma]

Oh damn I'm getting driveshaft failure symptoms as well. 66k on a 2002 115TDI Alhambra. On top of everything else I hope it gets me through to the new year.....

[t1Star]

Thanks for that,

 

I took the car to a an apparent 'specialist vw' he said the gearbox would have to be stripped and reconditioned. This female end replacing that is it a specialist gearbox guru job. Also somebody mentioned that the diff may have been damaged. The clicking noise is quite serious - I am having it sent to be reconditioned this weekend. Hopefully that will sort it out. :lol:

[Bigjeeze]

Sorry to disabuse you TIstar - but once you have removed the intermediate shaft - just allen bolts - to remove the female splined shaft all you need is a spline type tool to remove a small screw- then it just pulls out - you don't even lose the gearbox oil. It is very simple indeed . Unless there is any other damage I would not see any need to remove the gearbox. The new part comes with all necessary seals etc - they are all fitted you just pudh in the new one do up the screw and re assemble!

[t1Star]

Sorry to disabuse you TIstar - but once you have removed the intermediate shaft - just allen bolts - to remove the female splined shaft all you need is a spline type tool to remove a small screw- then it just pulls out - you don't even lose the gearbox oil. It is very simple indeed . Unless there is any other damage I would not see any need to remove the gearbox. The new part comes with all necessary seals etc - they are all fitted you just pudh in the new one do up the screw and re assemble!

 

Hey no worries,

 

I am technical but in the area of industrial automation rather than mechanics and cars. So all the advice is really appreciated I will have a word with the mechanic in the morning and post back with whatever the result is. :lol:

[t1Star]

Hi All,

 

Sorry for the late reply, just been tied in work too much.

 

Thanks very much Bigjeeze.

 

Replacing the female flange did the job.

 

There is an inner metal circular piece on this which had broken and a part of it remains on there. As this item seems to be spring loaded in its assembly position going from reverse to forward etc caused the clanking noise. I have a feeling this may have caused the whole problem in view of other posts on this site. Although the splines are not at all worn as can be seen from the other photo. :P

 

Lets hope it keeps going now!!!

[TimsBamma]

Oh damn, re my previous post last night on way to Folkestone to go SnowBoarding for the weekend came off the M20 because of the Sea France lorry stack went cross country at junction in middle of no where turn right apply accelerator and BANG, no drive.

 

Yep I'm sure its this fault.

 

Got home at 2am.

 

Oh well, time to sort it out hope its not too much......

 

Guess I'm not getting some RS4 rims now..... <_<

[JohnR]

Bummer! Sorry to hear that Tim. Am driving mine over to Chamonix getting the 19:35 ferry next sat (15th) to ski/board sunday to friday, back sat 22nd. Staying in bunkhouse at Vallorcine (bout a tenner a night) if you fancy sharing the diesel costs! Snow conditions looking excellent. PM if interested!

 

John

[TimsBamma]

John

 

You're a gent, thanks for your kind offer, well I've just got back after 2 of 3 days so it wasn't a total loss.

 

Just as we left last night (coach back) it started snowing again.

 

Hopefully your week in Chamonix should be excellent.

 

Well, time to start raiding the piggy back to get this driveshaft fixed.

[TimsBamma]

Well I'm now

[Ginettamad]

I have a 99 TDi 110 which had a new box a few years back.

I have the OFF side ABS ring on the CV joint spinning loose so I orderd a new CV and got an Pre 2000 one only to find mine has the later smaller splined drive shafts possibly due to the box change?

The garage has now have found the intermediate bearing has come apart holding the OFF side driveshaft. So is this also a very expensive part to replace? No idea re the drive shaft flanges but all this due to the ABS ring comming loose!

Apparently there are numerous types of bearings and carriers so god knows what my bill will come to?

Harvey