WA: Back doors 'Boring'

The week that was...
What a shocker last week was.

Starts off on saturday.
Finally got the turbo parts and exhaust all back together and on the car by lunchtime Saturday. Start her up and check everything but the oil feed line from the block is leaking....and then it stripped the thread. All happened just after 12 when everything closes down.. Damn.

So Monday i go to a fitting shop and get the correct fitting (yes the other one was wrong which is why it was leaking obviously) get back and fit it and bam! No oil leak. Woo time to drive the car...until i look under the rear and notice a big pile of oil. Damn! All the expensive haldex oil had leaked out from where the controller is. Sigh. So call up and try and get a new tube of haldex but unfortunately it couldn't come in time.

Tuesday i picked up the new tube of haldex and got home. Fixed the gasket which i think must have been around the wrong way (its quite the pain in the ass to do but no excuse). Went to fill the haldex and boom! oil goes everywhere. Doing it the same way i've done it 5 other times it manages to pressurize and blow the bottom of the haldex tube out and oil goes everywhere. Nuts another bunch of expensive oil down. Call up another place for a new tube and same deal as monday. This nearly broke me.

Wednesday. Pick up the new tube and get back to the car. All goes well with putting it in this time and no hassles. Start the car and get it off the ramps and boy was it good to drive it again. Put a smile back on my face. Drove it for Thursday and Friday loving every second of it.

Saturday Morning: Heading off down south to go kart racing pulled up at the lights and as it goes green i hear this awful thunking noise. WTF? pulled off to the side of the road expecting maybe a wheels come loose or something but they are both fine. Look in the engine bay and the passenger side drive shaft has worked all the bolts loose and came off. Freaken hell. Another $110 tow home for 3km isn't fun. Get the car back in the drive way and the end of the driveshaft comes off on the road but to be expected.

Sunday. Get the car back into the garage and notice fluid leaking out strangely. Wanted to see what damage had been done got the car up on ramps and couldn't believe my eyes when i saw it. This ****ing car hates me so much. 3 Days... 3 freaken days is how long i had the car before the next major failure.
http://www.vwwatercooled.com.au/foru...vwxosnc7-2.jpg
http://www.vwwatercooled.com.au/foru...cs7cdaiu-2.jpg
My new inspection window.
http://www.vwwatercooled.com.au/foru...o2jjhwen-2.jpg

So time to rebuild the gearbox. Well at least its kinda an excuse to change over the final drive that i brought and strengthen the box but i wish i could have done it on my own accord. Not looking forward to the bill on this one. Think it may go over the turbo sigh.

Lets see if i can get this running before the dyno day :(

Quote:

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Originally Posted by Back Door Shenanigans.

.....oh well **** happens i suppose. Still sucks spending $1000 to replace something that shouldn't have broken, specially when i could spend it on improving other stuff haha.

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Wish i didn't have to eat my words... again

no good man!
what went though the box?

Keep at it!

If it makes you feel any better, this is what two of my spark plugs looked like after 1500kms haha
http://www.vwwatercooled.com.au/foru...ecf289bf-2.jpg

Quote:

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Originally Posted by dylan8

what went though the box?

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From these angles it looks like it was the flailing driveshaft after it broke free.

Are you supposed to loctite those bolts when they go back in?
Thats the longer front shaft too, isn't it? Did anything else cop a pounding?

Quote:

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Originally Posted by dylan8

no good man!
what went though the box?

Keep at it!

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As tinto said i believe the drive shaft moving around when i moved the car off the road.

Trying to, cars really testing my patience. Keep joking about the next thing breaking until it gets there. This ones going to end up costly again as well.

Quote:

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Originally Posted by trickysimon

If it makes you feel any better, this is what two of my spark plugs looked like after 1500kms haha

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Jesus how'd you do that?

Quote:

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Originally Posted by tinto

From these angles it looks like it was the flailing drive shaft after it broke free.

Are you supposed to loctite those bolts when they go back in?
Thats the longer front shaft too, isn't it? Did anything else cop a pounding?

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I don't believe they need it but sure as hell are going to get them now. Nah shorter shaft on the passenger side. The end cap of the drive shaft came off and got run over so not sure if i can get that separate all though it seems as though i should get a new drive shaft anyway.

Small update.

Got the gearbox out after much cursing and swearing but only took 5 hours including removal of turbo and sub frame (just makes it a bit easier). Its a bit sad that i know how to do it exactly...

Resulting works after gearbox out.
http://www.vwwatercooled.com.au/foru...9itsbg4k-1.jpg
http://www.vwwatercooled.com.au/foru...ghsdz7cv-1.jpg

Finally bastards out
http://www.vwwatercooled.com.au/foru...wudyedaf-1.jpg
Transfer case removed
http://www.vwwatercooled.com.au/foru...xh4q1hkb-1.jpg

Damage to gearbox and driveshaft.
http://www.vwwatercooled.com.au/foru...nyxaqo3u-1.jpg
http://www.vwwatercooled.com.au/foru...otsdi6gu-1.jpg

Draining oil was a sparkly experience
http://www.vwwatercooled.com.au/foru...dewdmkft-1.jpg

Splitting the case was a bit of a pain in the ass, not sure if due to me being tired and frustrated or just like everything its just a pain in the ass. Major issue it getting the shifter tower out. Once split it reveals far more glitter.
http://www.vwwatercooled.com.au/foru...u9tmvepu-1.jpg
http://www.vwwatercooled.com.au/foru...ydswvzgh-2.jpg
http://www.vwwatercooled.com.au/foru...kes19jk1-1.jpg
http://www.vwwatercooled.com.au/foru...a1cgei5l-1.jpg

Time to order up some bearings and seals and then decide weather or not i can rebuild it myself or should i take it to someone.

Also, if anyone notices some slop in their gear shifts i can bet its caused by this shifter pin which runs in the guides for the H patten. Would be an easy fix
http://www.vwwatercooled.com.au/foru...al2wbtp3-1.jpg

At least the new final drives will go in sooner than i expected. Looks like im seeing double.
http://www.vwwatercooled.com.au/foru...4imdgodh-2.jpg

You're supposed to replace the driveshaft bolts everytime they are removed and torque them to the manual. FYI no-one ever mentions locktight but after seeing many gearboxes with holes in them, I always replace and locktight ;). By the way for the sake of $200 or so, get a new driveshaft, save yourself thousands.

Quote:

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Originally Posted by The One

You're supposed to replace the driveshaft bolts everytime they are removed and torque them to the manual. FYI no-one ever mentions locktight but after seeing many gearboxes with holes in them, I always replace and locktight ;). By the way for the sake of $200 or so, get a new driveshaft, save yourself thousands.

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Yeah like a lot of these bolts they are stretch bolts. Too bad it would typically have to come from Germany if i wanted to get them from the local dealer. I got replacements coming this time and will locktite the bejesus out of them.

The drive shaft is fine. I've got the lobro apart and will inspect everything but that wasn't the fault. A good rebuild will do it no problem. Not ideal but you can't get driveshafts for these for $200, at least $400USD each plus shipping for the ones i would need. That ends up over $1500

I love this thread. When things are all back together and your car doesn't miss a beat you'll know that everything you've done has been worthwhile :driver:

I remember my Dad used to joke about my first car, that if I'd known when I'd bought it that I was going to replace pretty much everything on it, I could have saved myself some time by jacking up the horn and sticking a new car under it.

whatever happened to this ??