Operation total F*** up!

[Mouzer23 0]

Sigh,

Hey guys ever had the feeling you've started something you cannot finish? That's exactly how I feel.

I'll start from the beginning.

About a week ago I was in my usual sprightly mood in my 4Mo and pulled off from a standing start (quite violently) going through gears 1-3 and then slowing for a traffic light. No problem. When the light turned green and I pulled off I heard the worst sound you could imagine. Almost like a crunch and then something engaging jolting the car. I immediately pull over and checked for leaks and to see what I could see which was nothing.

Some mates and I jacked the car up (all 4 wheels) and then started it and put it into gear. The driver's side wheel was not turning and passenger side rear wheel was turning. When you stopped passenger side front you would expect the driver side to turn, but nothing. We assumed the rears were turning due the stability control sensing the front was slipping?!

What we then discovers was that drivers side front "Flange shaft" had actually pulled out of the gearbox and the shaft was not actually seated correctly, thus no drive.

Next Fail:

I then took it to a CV specialist who I "assumed" knew what they were talking about. They took one look at it and said it just need to be knocked back in. So they knocked it back in with a 4 pound.

Drive was instantly restored to the front wheels and the car felt normal again. I was however worried about what was holding that shaft in and what would prevent it coming out again.

So I take a look on ETKA and my whole world came crashing down. There is a pressure spring and parts meant to be on that shaft that are just not there. The agents said you should never be able to just hammer it back. You would need a special puller to pull the shaft back onto the box. F*******k.

So I attempt this mission on my own. I buy the spares and start stripping see pics.

I get the shaft out with the inner CV and I can see the flange. I eventually get it loose after about an hour of careful hammering and prying. I then find there is a cover sitting above it preventing me from removing it. I get the cover off and then hit another fail. The flange shaft cant slide past the bottom end. The sump and bottom end of the block are preventing me from taking it completely out and inspecting it

This is a diagram of exactly what im talking about.

I fear I may need to take out the gear box "OUT" if this is the only way then I guess it has to be done.

How would I do this and how big of a mission is it?

Any help would be awesome guys.

[UnitedMotorsport 55]

You have the wrong ETKA diagram. The one you have is for a 2wd car.

The 4wd diagram shows none of the parts that you mention and you are only missing the bolt in the centre of the shaft that holds it in,

The part number of the bolt is: 097 409 359

Push the shaft back into the gearbox, put this bolt down the hole you can see in the middle of it, and do it up. Put everything back in place that you have removed and your car is fixed.

[Mouzer23 0]

Dude you are right, The Agents have screwed me. Thay gave me the wrong diagram!! If i wanted to replace the side shaft seal, would that mean gear box out?

[UnitedMotorsport 55]

No.