WA: Back doors 'Boring'

[Back Door Shenanigans.]

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.


My new inspection window.


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

.....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.

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

[dylan8]

no good man!
what went though the box?

Keep at it!

[trickysimon]

WA: Back doors 'Boring'

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

[tinto]

what went though the box?

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?

[Back Door Shenanigans.]

no good man!
what went though the box?

Keep at it!

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.

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

Jesus how'd you do that?

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?

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.

[Back Door Shenanigans.]

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.



Finally bastards out

Transfer case removed


Damage to gearbox and driveshaft.



Draining oil was a sparkly experience


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.





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


At least the new final drives will go in sooner than i expected. Looks like im seeing double.

[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.

[Back Door Shenanigans.]

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.

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

[RolfGolf]

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

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.

[PassionGarage]

whatever happened to this ??

[geoff_gti]

How's it all going dude?

[BoraBora]

Wow. Epic thread. Is your car alive again?

Edit: ahh guess not just found your EOI turbo parts thread. Good luck.

[Back Door Shenanigans.]

Ok,

So it seems about time that i did an update on the car. Can't believe how long ago i updated this thread . Unfortunately it looks like a combination of being over the failure and my phone being crap means there is not much photos sorry. It also happened so long ago i must have forgotten a lot of the pain.

Last time i posted was when i was getting the gearbox rebuilt. Before sending it off i had to upgrade a few internals.
Old Final Drive with rivets

Rivets drilled out

Ring gear off

Bastard rivots really didnt want to come out.

Using my grandfathers old bench vise the wrong way leads to missary.


More rebuild **** and rivets for the diff, used two packs in the end after some of the threads screwed up when inserting them (probably to do with poor workmanship :S)


I took the opportunity to do some shift fork upgrades whilst i was here. Shift fork with rivet

Rivet drilled (different shift fork i know, not sure what happens with the photos here)

Tapping hole

Stainless steel hex head put in M8 i think

Joined back

Bolt welded up using TIG, was a lot easier than expected.

Bolt heads ground near flat for clearances.


Also noticed the shift selector was broken, and so was the one with the diesel gears, So had to get a third tower shipped to sort it out, sigh.

[Back Door Shenanigans.]

The guys i took it too in Belmont did an awesome job getting it back together with the new diesel gear ratio that theoretically mean the bora can now do 360km/h They even painted it, not bad for $800!


Also cleaned up a few other parts like cv joints etc.

New Bearings

New engine mounts

Audi TT cast a arms


I managed to get it all back together for some dyno time. Was a little dissapointed with its power for the boost but still not too bad, ended up leaking all over the place which they weren't too happy about Can anyone pick where boost



Then it turned bad. This was a nightmare that started around may last year i think...ended in september or so. Allthough in the end im just glad he ended up paying, thought it was going to go to court.

[Back Door Shenanigans.]

Then it got even worse....props to those who see whats wrong on the first picture

Another tow truck, shes up to 4 roadside pickups now....


Haven't got much photo of some of the stuff unfortunatley.
Big hole in the down pipe

Patched,

Welded with a new O2 bung for wideband


Trophy pieces now.


Looks like a bolts come loose on the driveshaft coupling allowing it to detach but still spind from the rear wheels taking out everything in its way.

Sorry need to take some photos of the failure but you can see below when it repeats itself....

I eventually patched it up in between it going to the panel beaters to get fixed so it can drive again. Had to figure out why clutch stopped working as they couldn't move it..freaken line had come out.

Back together with original tails in...still unsure on where to go with the tail lights as i can't easily find the ones i had.