Very Bad Clunking From My Refitted Gearbox And Kazz Diff

[pip470 61]

Ok Ive also read spikeys thread and a couple of replys seem relevent to me but I didnt want to hijack his thread. So, i did the Euro trip with this engine and gearbox combo, I thought the diff worked as it should and was a really nice experiance, at slow speed it would clunk and release to allow the plates to rotate as it should.

Now I took the engine out and rebuilt it, popped it back in and now I have some issues.

 

It doesnt like corners at all, its like the diff is not releasing and its just clunking if any kind of power was applied, at first it was even clunking in a straight line and the whole engine had a side to side wabble. I know ben also had this problem with the engine movement and found it to be the drive shaft. So i pulled back the cv and sure enough one of the rings holding all the needle bearings had come off. Great I thought as well as being a bit peeved because I checked it before i fitted the shaft and all seemed well. Anyway, great I though that will fix it, It did fix the engine wobble and clnking in a straight line but not the cornering.

 

I jacked up the front and put the car into gear whilst my mate was turning from side to side on the steering wheel. The shafts were rotating nicely with no noise what so ever.

 

So that brought me onto the diff not releasing causing both wheels to try and turn at the same speed on corners and causing the shafts to knock. ( it is definatly the drive shafts knocking, not sure how there knocking)

 

I am really stuck with this because another spanner in the works is that i can get the diff to unload by leaving one wheel on the floor and turning the other.

 

So i racked my brain, and the only thing really that i changed is the gearbox oil. I went from gsfs 75/80 cl5 to halfords own 75/80 cl4. Its the only thing that would kind of make any sence. I dont want to waste £15 worth of oil if any one can confirm this sounds feasable or not. Just to confirm, the drive shaft i just replace was a known good one, as were the two that were fitted in the firstplace as they came from the car. I am running 1.9 gti hubs, and the setup is exactly the same as when I did 3000 miles accros Europe.

 

Thanks Phill

[Anthony 1,003]

Are you sure that the driveshaft you replaced is good?

 

Plate diffs are very sensitive to worn driveshafts in my experience, and driveshafts that were OK on an open diff can knock and make a racket on a plate diff.

[pip470 61]

Thanks for replying Anthony, I refitted the same ones i removed after the Euro trip, so the first two, had been fitted to the kaaz dif accros Europe, when refitted I got the above problems, The one I replaced it with I made sure visually and also tried to see how much rotating play on each end and it felt really new and un used. I really dont want to spend money on two new shafts and have to give the ones I think or ok in exchange only to find the problem is still there. But it looks like I may just have to clear that posiibility completely.

[pip470 61]

Ok, well, I was going to change the oil tonight to see if that would work but when I drained the twoday oil out it was black with particles of shiney ally mixed in. Definatly not a good sign. Not sure what im going to find but will remove the box completely on monday/tues depending on sleep patterns. I have two new drive shafts and im hoping i have another gearbox in the shed.