TD6 clonk in frontend

Mine has developed a new "click" at the front left now :/ only under heavy load in the car park or heavy breaking in forward or reverse.

Investigations will begin soon as it is a little warmer
:censored:

This sort of fits here, so I'll tell the tale here rather than start a new thread. As I've posted before I had a small clunk in the rear somewhere - after checking over and tightening everything in the back and finding the diff mounting bolts a bit loose, the clunk went away - took it for a nice long drive, gave it some stick etc - all good.

I took it for a RWC yesterday as I'm selling it and when I picked it up last night and was driving it home, the clunk returned - new and improved - bang, bang, clunk, scrape, stop.... :(

Limped it the 1KM home in 1st at idle and came inside quite dejected - this morning had a good look under the car, nothing loose, bugger - thinking the rear diff had gone to God. Called the guy who's buying it and explained the situation.

Anyway, while buying shocks for it today, at British Car Components I described the clunk to Dave and he said it sounded like a uni joint failure. Being an IRS vehicle and how the rear tailshaft connects at the TC and diff, I said I'm pretty sure it's one piece (remember you can't see the tailshaft - just the ends - it's hidden behind covers). Anyway, Dave bought up the drawing of the driveline on Microcat - and sure enough, he was right - a 2 piece shaft with centre bearing.

So, quite excited I got home just now and pulled a cover off to reveal....

Yep, a stuffed uni joint and centre bearing...

Dave was 100% correct - I'll start calling him the Guru Mark II...:D

I'll know more about the damage when I remove the shaft this weekend, so I'm not sure if it is salvageable yet or the damage has been wide spread. Not sure what happened first - the Uni falling apart that then damaged the centre bearing or vice versa.

Another interesting point is that the car had just had its first test for a RWC - and this was not picked up... Only rear shocks - ****ing out oil - and a few minor things.

They did tell me they weren't familiar with the vehicle, so maybe they made the same assumption as me and just checked each end where it mounts to the TC and diff.

Anyway, just thought I'd share that - it manifested itself as a small clunk clunk clunk when driving off, it didn't get any worse until it totally failed.

Maybe worth checking if you can't locate a clunk in the rear somewhere.

Glad to hear it didnt happen as speed! Also great news that its not the diff itself :D

any pics of the damage yet?

Will post some tonight. Got what's left of the centre bearing out, just trying to get the shaft out - it a bit of a pain to do - would be a breeze on a hoist.

All the bolts are out, front is disconnected but where it meets the diff is stuck - the tolerances are very tight - it fits on a large spigot both ends - like the driveshafts do on the diffs if you've ever had those off.

I'm heading back outside soon to have another go.

Well, nothing to show tonight - the tailshaft is stuck fast to the diff. Spent 2 hours under there trying to shift it but to no avail. Will try again tomorrow, hopefully it's not raining.

Don't envy you mate, sounds like it requires a lot of swearing.

I think I've worked out how to shift it. I'll reattach the front end and put it in gear to see if I can break the seal at the back. I can't imagine a bit of surface rust staying there too long if I do that. ;)

Well, that was harder than I thought but it's sorted. Pictures to follow shortly.

Congratulations, well done. What was the trick after 4 hours of trying?

There's a slot machined into the flange to stick a screwdriver in - it's very hard to see up there so I missed it - I'm about to start a new thread on this whole job as there is a heap to it....