Looking for any suggestions or experience here folks.

My Lad has a 2003 1.4 16v Golf. It has just snapped its 3rd NSF inner drive shaft.

We bought it last June for him to learn in he passed his test in Ocotber and all was fine,

we had the clutch changed in January at the same time it was noted the large gearbox mount had broken so this was replaced also. The Drive shaft broke in May while turning right. It then broke again about 100 miles later while turning right and it has just broken again 700 miles later while turning right.

 

I cannot find anything obvious and neither can my (very trusted) mechanic.

 

I have put a lot of work into this car for the lad and it would be a shame to have to give up on it.

 

Any help / advice would be greatly appreciated.

 

Cheers

Looking for any suggestions or experience here folks.

My Lad has a 2003 1.4 16v Golf. It has just snapped its 3rd NSF inner drive shaft.

We bought it last June for him to learn in he passed his test in Ocotber and all was fine,

we had the clutch changed in January at the same time it was noted the large gearbox mount had broken so this was replaced also. The Drive shaft broke in May while turning right. It then broke again about 100 miles later while turning right and it has just broken again 700 miles later while turning right.

 

I cannot find anything obvious and neither can my (very trusted) mechanic.

 

I have put a lot of work into this car for the lad and it would be a shame to have to give up on it.

 

Any help / advice would be greatly appreciated.

 

Cheers

 

Not intending to sound like an ass, but have you considered it could be driver abuse?

 

What part of the shaft is snapping?

Edited August 27, 201510 yr by Funkysi

Are you using OEM parts?

 

I have read that pattern parts have been known to separate at the gear box end as apposed to snapping.

Something to do with possibly being a tad shorter.

Its a fair comment but I have been in it with him when it went on one occasion and both other corners it snapped on cannot really be

taken with any 18 year old exuberance. No marks on wheels or tyres to suggest hitting kerb either.

 

He is a pretty honest kid (we all say that I know) he fesses up to stuff I would not have owned up to at his age to my old man.

 

It is a real shame cos it is a great first time car and I have put discs, pads, suspension, tyres, cambelt change, new followers etc etc on it and it would

be a real kick in the Taters if this beats me.

Are you using OEM parts?

 

I have read that pattern parts have been known to separate at the gear box end as apposed to snapping.

Something to do with possibly being a tad shorter.

 

Again a good call. Yes fitting OEM and it is snapping not pulling apart. It has snapping on the inner NSF all three times

If its OEM then does it not have a warrenty on the shaft ?

It does and so far we have snapped the original in May so bought a new OEM one and fitted, Snapped that 100 miles later which

was replaced free of charge and now 700 miles later we have snapped that one. They are not going to keep replacing them, I need to find

Root cause.

Has the car been lowered do you know?

Or is everything stock?

Has the car been lowered do you know?

Or is everything stock?

 

Everything stock suspension and wheels (insurance needs) Car is straight, no signs of a shunt or anything bent.

Engine mounts worn causing excessive movement and loading

Engine mounts worn causing excessive movement and loading

 

Garage has checked these and have given them a clean bill of health also checked all 3 gearbox mounts:crying:

Have the CV joints been replaced lately? Not sure if there's a way of testing the car's own differential - those really are the only other things that could cause this if everything else is ok.

Do the steering track rod ends seem to be fitted with a similar length of thread protruding, if they are uneven and the steering wheel has been taken off and re-centered than perhaps its putting undue strain on in a right hand corner ?? just a guess

Something is not quite straight by the sounds of it.

First thing I would do is the old tape measure from wheel centre to wheel centre on either side as there may not be any obvious shunt signs but it still could have happened.

Also do it on full lock each way.

Could be a slightly bent leg which depending on the bend might not be spotted with the steering straight

Even if the alignment is out and/or the suspension is damaged slightly the CV joints should be able to take up a large proportion of that error.

Edited August 27, 201510 yr by Funkysi

I am just hazarding a guess.... Has the wishbone been changed for a pattern part on that side? or too short?

If so It could be too short and putting strain on the longer driveshaft, causing it to flex slightly causing vibration fatigue to the shaft?

Only an idea.... If it were being pulled apart it would pop out of the gearbox..... so must be under tension?

To snap the shaft, one end is stopping/ turning slower and the other continuing to turn. Also are the driveshafts weighted? out of balance?

Could also be the diff inside the gearbox?

 

 

Edit:- Just found this article for you.....

http://www.justanswer.com/vw-volkswagen/4ezcs-vw-golf-fifth-passenger-side-drive-shaft-fail-gearbox.html

Edited August 27, 201510 yr by veilside01702

Something is not quite straight by the sounds of it.

First thing I would do is the old tape measure from wheel centre to wheel centre on either side as there may not be any obvious shunt signs but it still could have happened.

Also do it on full lock each way.

Could be a slightly bent leg which depending on the bend might not be spotted with the steering straight

 

Tried that all OK. Cheers

 

- - - Updated - - -

 

Do the steering track rod ends seem to be fitted with a similar length of thread protruding, if they are uneven and the steering wheel has been taken off and re-centered than perhaps its putting undue strain on in a right hand corner ?? just a guess

 

All appears even Cheers.

Have the CV joints been replaced lately?

 

Good point I have replaced the whole shaft this time rather tan just the inner piece.

 

- - - Updated - - -

 

I am just hazarding a guess.... Has the wishbone been changed for a pattern part on that side? or too short?

If so It could be too short and putting strain on the longer driveshaft, causing it to flex slightly causing vibration fatigue to the shaft?

Only an idea.... [/url]

 

Interesting. Yes both sides have been replaced last year when we first got the car. I need to find the measurements of a genuine wishbone to check this Thanks.