Club 80-90 Forums

Dear Vangels,

1989 1.6 td high top.

I had an unfortunate experience a couple of weeks ago where my near side half shaft failed just outside Farnham in rush hour. The bolts at the gear box side had failed.

Prior to the failure, whenever I changed gear and released the clutch, no matter how gentle I was, one could hear the deep metallic 'thump', as the load was taken up.

I remember last year when I took both shafts out and replaced the cv joints, that the gearbox flange had play in it, both back and forwards. I wondered at the time if this was normal.

I assume that if there is play at the gear box end, this sudden taking up of the load must place additional stress on those bolts.

I have replaced the bolts with the splined ones, but I can still hear that thump upon load take up. Is this a worn gearbox problem?

I am rather sad at the moment, because I don't trust Wilma, at the moment, and will not be taking her out for an extended trip until, I can resolve this issue.

Any advice would be of great value to me,

regards, Thatsrustytoo.

When you say you replaced the bolts - all six or all 24? And have you recently checked that every one of them is in place and tight? What make of CV joints did you buy?

There is a certain amount of play in gearbox flanges (more one side that the other apparently) but a 'clunk' is nearly always CV joint play or loose bolts. I mention this because I once had the misfortune to buy what (at the time) seemed a good deal on four CV joints. They didn't even last a year. Became clunky as clunky things. Ebay I might add. Changed for GSF's best ones and had no probs since. Its also easy to miss loose outside CV bolts due to the cramped access, and it tends to be those that go rather than inners.

Finally, check your engine mounts

Like most components that move, wear in one part can create wear in another but in my experience, good CV joints, bolted up properly, will give years of troublefree service.

Thanks Covkid for the advice.

I only changed those which had become damaged, but all were replaced last year when i took both half shafts out and replaced all cv joints with new ones from JK.

As some play in the flange is normal, the play must be in the cv joints or fixing bolts.

I shall check them, and the engine mounts.

Many thanks,

thatsrustytoo