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Thread: Broken Crankshaft?

  1. #1
    Join Date
    May 2009
    Location
    Tatura, Vic
    Posts
    5,455

    Broken Crankshaft?

    This morning when I started the Disco I heard some unusual knocking noise from under the bonnet. (300Tdi)

    When I lifted the bonnet the noise had gone so I headed off to work.

    About a click from home it died. My first thoughts were timing belt, so tonight I started dismantling the front of the engine.

    When it came time to remove the harmonic balancer bolt I discovered something more sinister.

    My method for bolt removal is to put a spanner on the bolt and hit the key, which I did. The starter motor sounds like it is working but the balancer did not turn.

    I now suspect broken crank so I removed the small inspection plate at the front of the bell housing. When I turn the balancer the drive plate/ring gear also turns.

    It got late so I will investigate more tomorrow.

    Anyone got any thoughts on what might be the problem?
    Dave.

    I was asked " Is it ignorance or apathy?" I replied "I don't know and I don't care."



    1996 TDI ES. 2003 TD5 HSE

  2. #2
    Join Date
    Apr 2016
    Location
    Melbourne
    Posts
    2,929
    Quote Originally Posted by d2dave View Post
    .....

    Anyone got any thoughts on what might be the problem?
    To me, at first sounded like a broken (worn) Woodruff key.
    But if ring gear turns, then balancer is connected to crank.
    Also a little confused(maybe just the choice of words) .. you said "spanner and hit starter", which I assume you mean the large 27mm(1 1/16") bolt to remove balancer off crank. Spanner or socket and breaker bar.

    Anyhow, after reading the last bit, sounds more like starter is spinning but not engaging, so it's spins, but it's clutch is not engaging onto the ring gear. Have you confirmed this either take the starter off or check ring gear whilst hitting starter?

    Another alternative: you said "drive plate and ring gear" so can we assume an auto? You didn't say flywheel. Maybe cracked drive plate? Maybe still has just enough friction to turn when rotated slowly, but once starter is running at speed, just not enough and drive plate overcoming engine compression is harder compared crank turning the drive plate.

    So if you have auto, most likely aircon too. Check the timing belt inspection port for timing belt happiness too.
    Cheers,
    Arthur.

    '99 D1 300 Tdi Auto

  3. #3
    Join Date
    Jan 1970
    Location
    St Helena,Melbourne
    Posts
    13,567
    Woodruf key sheared ?
    MY08 TDV6 SE D3- permagrin ooh yeah !
    98 TDI AUTO SE DISCO - gone and will be missed.
    2003 Dingo offroad camper trailer
    1998 Triumph Daytona T595
    1974 VW Kombi bus
    1958 Holden FC special sedan

  4. #4
    Join Date
    May 2009
    Location
    Tatura, Vic
    Posts
    5,455
    I haven't yet had time to do further diagnosis as work sent me to Syd Fri night.

    I am now back home and have read replies.

    Now things like starter motor, broken drive plate, woodruff key etc would not stop the engine.

    Some of the above would prevent starting and driving, but I was driving and the engine just died

    Woodruff key is definitely ruled out, as when I turn the pulley all the rocker gear is working.
    Dave.

    I was asked " Is it ignorance or apathy?" I replied "I don't know and I don't care."



    1996 TDI ES. 2003 TD5 HSE

  5. #5
    Join Date
    Jan 1970
    Location
    St Helena,Melbourne
    Posts
    13,567
    If the key failed then timing gear won't spin neither will the pump, it might just slip under load.
    MY08 TDV6 SE D3- permagrin ooh yeah !
    98 TDI AUTO SE DISCO - gone and will be missed.
    2003 Dingo offroad camper trailer
    1998 Triumph Daytona T595
    1974 VW Kombi bus
    1958 Holden FC special sedan

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