Loss Of Drive Under Minor Load

[jonmelkay]

Hello, 

 

 

My 2000 Mk2 Galaxy 1.9TDi manual  developed a drive fault last night.

If you pull off gently like driving on sheet ice it's fine and you can slowly build up speed and change up through the box. No noises etc but, if you accelerate just too much or hit a hill and it has to use some torque there's a fast judder at first followed by what sounds like metal bouncing off teeth in a fast ringing style rather than grinding or banging and the revs climb as if the clutch is slipping. If you lift off it all settles back down again. 
Once you hit a hill you can continue up it as long as you keep it in a lower gear with the revs around the 2000rpm mark but any more than 2500 (revving too quickly) and less than 1500rpm (labouring) and it spins up.

If stationary with 6th gear selected you slowly lft off the throttle at half revs it just spins up, again with the ringing type sound.

It's not a standard quiet clutch slip  where the revs build but the speed remains the same. The clutch was done about 15000 miles ago and a drive shaft was changed as well according to the seller. One of the drive shafts is clearly newer than the other

So any ideas, likely fixes and costs etc???

Thanks yet again in anticipation

Jon

[daddyfixit]

noises -----sounds like flywheel has gone to met its maker ??   plus a clutch slipping again

 

if so, its gearbox out and clutch off again

Edited December 25, 2015 by daddyfixit

[jonmelkay]

daddyfixit

 

Thanks,

I've been told it might be the DMF or even the intermediate drive shaft,

The one thing I don't understand is if it's the shaft will it grip at low load but slip at higher load or just slip across the board?

If it's the DMF can it be an intermediate fault or is it a once it's failed it never works again?

 

The half shaft is doable for me, the DMF means its on eBay for spares or repairs :((

[BrianH]

The teeth on some just aren't long enough there's been a few people on here with the problem. There were some reengineered ones done. Motomax I think should match some posts here.

 

If it is the shaft you may be able to see powdery residue near the joint area.

[daddyfixit]

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).

[BrianH]

The fast ringing sound referred to makes me suspect its the shaft on its way out - either way get the undershield off and looking should tell you one way or the other (if the shaft looks ok then the clutch would seem likely as you've said).

[jonmelkay]

In one last desperate effort I've marked the shaft at the joint and tried the 6th gear pull off to no avail. The shaft didn't move, let alone show any slip which tells me the drive isn't getting that far. Now it won't go into any gear so I believe, as daddyfixit said,  it's the clutch or somewhere in the clutch are e.g. DMF that has gone.  :( :( :( :(

 

I don't have the ability or tools/venue to do the work myself nor the money to spend on something I've now lost faith in so it'll go on eBay in the next few weeks for spares or repair sadly.

 

Shame it's been a good workhorse

 

Thanks for all your help with this

 

Jon 

[daddyfixit]

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 ??

[BrianH]

Sounds like you've fallen victim to a cheap clutch if its only done 15000k before failure. Did you get the clutch done or was it prior to your ownership? It might be still under warranty?

[jonmelkay]

Yes I suspect cheap clutch by previous owner for sale.  No warranty..

[BigDog]

Jon,

 

I see you're in South East - I might be interested if you are fairly local to me. Where are you located - is it on eBay?

 

Thanks,

 

Matt