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Discussion Starter · #1 ·
Hi all,

Im looking for some advise on a problem I have with my 110 TDI. I fitted coil overs on friday and Im running 225/40/18 tyres so I think this has helped cause the problem. The car drove brillantly on the new suspension and the grip through the corners was amazing. On Saturday after a long trip I tunred a corner to the right and heard a cruch type noise.As I tried to accelerate out of the corner I had no drive. I immediatly pulled over (coasted) and had a look under the car. Sure enough the driveshaft didnt look to be in too good a shape. The gaitor at the gearbox end was twisted which led me to believe that the driveshaft had broken. But I have being told by a local VW parts dealer I might be lucky and just have to replace the knuckle at the top of the driveshaft. He told me it sounded like the bearings had gone and has left me with a spinning drive shaft. I wont know the full story until I remove the shaft and have a proper look.

I have searched the fourms and did not find any simialr thread that descibe these symptons. A smilar thread resulted in a new gearbox replaced under warrenty by VW. Well I hope this aint the same for me as Im not under warrenty and will be footing the bill myself. I have also being told its a fairly common problem with lowered Golfs running wide wheels as the extra stress can result in failed bearings and thus leaving the driveshft spinning freely. Ill post tomorrow to let you know how I get on with the removal of the shaft and if its obvious which parts need replacing. But for the moment if anybody has had any similar experience please let me what was required to fix it.

The way it stands the car will be off the road for a few weeks because between my normal job and my limited mechanical experience its gonna take while to sort out (if its the knuckle that needs replacing its gonna take 6 working days to get sent over form Germany).
 

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There are known problems with the ARB fouling the OS driveshaft when lowered. I have a 30mm drop on Eibach springs and I have to run adjustable links to stop the ARB hitting the DS.

I'm running Bonrath adjustable ARB links, the other option is to replace the ARB with an aftermarket one as they have more clearance.

Who's coilovers are your running as the KW ones also have connection points for either the R32 or S3 one which works in a different manner so doesn't have the same problem.

There have been some reported cases of ARB's damaging the OS DS.
 

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Discussion Starter · #3 ·
Yes we checked the ARB for damage and it dosent look as if the driveshaft has fouled on it. Its something that was noted in the fitting instructions of the coilover kit (Weitec BTW). Ill deffinetly give it a closer look this afternoon but the ARB and driveshaft have plenty of gap between them. The warnings in the fitting instructions were about 50mm driveshafts and mine were 46 (I think) so I wasnt too worried about them (but it was in the back of my mind).

Im fairly annoyed with the whole thing to be honest. I spent 6 hours fititng the kit on my own on Friday and then Saturday this has to happen. It makes ye wonder is it worth all the effort of modifing your car atll. I doubt this would of happend with my old 15" AvusII's and the wholly VW suspension.
 

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Ooh, that sounds nasty Mark.

Did that happen on the way home from Kirkistown ? Did you put it on the track at all ?

I've never seen any broken driveshafts mentioned on here at all, but I have read on tdiclub.com about someone snapping cv joints. I think it was mainly due an LSD up front and through the bends it just couldnt handle the stress.

Are you gonna do the repair with new parts ? Would you think about that scrappy in Cavan ?

Did you lower the car much on the coilovers ?
 

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Discussion Starter · #5 ·
Well theres no pulling the wool over your eyes Thos. It actually happened on the track :) Im totally sick over it. Im not going to go into the hassle I went through to get a tow truck home. Thankfully the AA cover my mate has came in handy and I got home for noting. I was onto the guy up in Cavan and he can get me a shaft for 100 quid or so and a trade on my old one (he can use the outters again). but Im dubious of using a second hand shaft. I fitted the suspension as low as it would go but raised it up a a bit as it was really slammed and when I gave it a quick test drive it rubbed on full lock. I didnt take any measurments as it was a right pain fitting the whole kit. I was left working with a tourch to fit the rears springs. But I would really recommend fitting coilovers as it nearly totally removes any body roll and still keeps a degree of comfort. Its a pity i didnt get more time to run them in but while the car was running it was amazing how fast it would go around bends without losing grip.
 

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Tut tut tut. So, you have a Mk2 GTI at home in a garage ? But yet you chose to take your daily drive on the track ? Mad man !!

Sorry if I let the cat out of the bad.

I wondnt mind a spin in your yoke the next time I see you, I'll take you out in mine, should be interesting to compare the Koni/Eibach setup to the coilovers.

Are the driveshafts specific to each gearbox/engine or are they the same across the mk4 range ? Just nick ones out of your Mums TDI !!

So, are you out in the Mk2 or on the bus ?
 

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Discussion Starter · #7 ·
Im out in my mams Mk4 1.4. 700 miles on the clock so its my job to run the engine in just right ;-) Haha about the mk2 - thats my baby - its too good to go on the track. The mk4 is just an expensive run around. I have had more bloody trouble with it then the mk2 aswell. It really makes me wonder why the hell I went to the expsense of buying a mk4 when the mk2 was grand and never gave any trouble. And Ill tell ye another thing, my smoky ol 110 was well able to cut it with the GTI boys on the track. I was closing ground on a few of the mk2 8v track cars that were there and i was told that the car looked by far the fastest taking the bends. I think when I get it back up and running Ill have to be taking it handy and not tryig to take corners at F1 car speed :) Sure Ill let you know how it goes with it and we can hook up for a spin (maybe you can bring along your VAG COM and check out a few things for me).
 

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Sorry, I thought your Mam had a TDI for reason - oh yeah, mine does !!

Sounds like you had a bit of fun on the track, until you had that little mishap.

Kinda gone a little off topic here now too, oops.
 

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Discussion Starter · #9 ·
Ahh yeah it was good fun alright. Track days are always fun, its just a bollox when something goes wrong. I didnt think I was pushing the car that hard to be honest. I wasnt jumping the kerbs and I thought i was taking it handy around the bends. Obviously i wasn't taking it handy enough and it caused the driveshaft to eat its bearings. I just hope its an easy fix and noting major like a gearbox job. It will thelast track day Ill be at for a while anyway. I might have to ivest in a track car and save my everyday motor.
 

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How did you remove the drivers side strut?

I noticed on mine that you can knock the hub off so far but then the driveshaft fouls the lower subframe. If you carry on hitting it would transfer the knocks to the other end of the shaft and into the Diff. I used a long socket extension bar and knock up from underneath the shock to get it right out.

Just a thought.. may be the reason for the inner CV/Bearing failure

Scott
 

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Discussion Starter · #11 ·
I didnt actually have to remove the hub atall. If you undo the bolt that holds the ARB onto the wishbone it should give you a certain degree of movement in the wishbone. This should be plenty to allow you to drop the strut out. Somebody else asked me a similar question at the weekend at thats the same answer I gave them. But it can cause the drive shafts to move in and out of their housing at the gearbox end. It popped out on me but a bit of fiddling and it popped back into position. Its the passenger side driveshaft thats is giving me the grief now.
 

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Discussion Starter · #12 ·
Well I stripped out the shaft last night. The innner CV (that bolts onto the gearbox) had broke up inside the rubber boot. The shaft itself is okay and the only damage I can see is the internals of the CV bearing. Ill be able to order one from VW but it wont be here until mid next week.
 

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Have you tried German and Swedish?

Don't know if they do them for the MK4 but they were dirt cheap for the mk2.

Scott
 

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Discussion Starter · #14 ·
Yeah I tried G+S but they dont stock do them unfortunally. Im able to get a driveshaft in Cavan which is about an hour and half form Dublin so it looks like my Saturday is booked out already.

Thx

Mark
 

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Same happened to me on the way to inters. Go to Ipswich got a little "carried away" at a roundabout, testing handling at speed. Next thing is bang inner joint went pop, no drive, stranded in a lay by for 4 hours waiting for the AA. Inters was great, the drive was worth it, but the ride back in the Trailer from Ipswich to Leeds was a nightmare. I managed to the get the shaft sorted from a Driveshaft specialist, using OEM parts for around £60 plus VAT, same day service.

Hope you get yours sorted soon. Decked suspension + 19" wheels + enthuiastic driving can lead to joint failing.
 

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It's pretty lame if you ask me that these joints fail so easily.... may raise my car if it is such an issue, I ran my mk2 on the deck with 17's for 60k+ miles of very hard abuse, never replaced a CV....

Scott
 

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Discussion Starter · #17 ·
Hey amge55uk,

I picked up the inner CV bearing I needed last night and fitted it with no hassle. So Im back on the road and getting used to the coil overs. I got the innner CV and boot kit for 72 euro so Im pretty pleased with that.

Does anybody know if a 150 TDI has an uprated inner CV joint compared to the 110 ???? Surley with all that extra torque from the PD engines they have uprated parts.
 

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Early 98 -00 TDI's have a smaller shaft in comparison to the later models. The later models definatley have a bigger shaft and revised joints, to cope with the 6 speed Gearbox. May be they discovered the joints were weak on earlier models and decided to uprate them, but thats not like VW. Like you say caged it is bit disappointing on VW's part to have such an issue on their "latest cars" when it did not occur on previous models. You might aswell add it to the current VW fault list:

ARB fowling shafts when lowered, MAF Sensors Failing, Coilpacks failing, Window regulators failing, corroding boot handles, rusting rear windows pillar arms, Alarms not activating on break in etc etc etc.......
 

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Quote: posted by MattyV5 on 16/11/2004 12:54:37

Old post i know but......

Why is the os driveshaft thicker ? can it not be replaced with a smaller driveshaft ??

Becasue it is longer than the other side I believe.... could be wrong
 
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