2005 2.0 petrol manual T5 drive train spline question .

[Sunny43.5]

Hi all well today after 250.000 kays decided it was time for some routine inspections . Drivers side strut / shock was completely stuffed the shaft just fell in and out of the housing with NO resistance . So replaced both front struts with some new ones , whilst I had the front up I noticed some very serious movement in the drivers side drive shaft . With the wheels off both sides the passengers side seemed fine direct connection through to the gear box housing so to speak with no free play . Drivers side had at least 15mls of free play in each direction you could turn the wheel and it would have the 15 mls of free play before it seemed to connect to the internal . Question would this be the dreaded drive shaft spline I have heard about ? I have noticed when slowing for lights that there has been an unusual sort of clunking like a tailshaft used to get in the old rear wheeled cars . Any way time did not allow for inspection but some ideas would be helpful as I still have some other front end jobs to sort out later . I might add that while driving the same side seems to generate a small noise like a growling rumble sound not normal methinks .Side bar I changed my sons timing belt and water pump yesterday on his Holden Astra shame VW don,t make it as easy to do , 2.5 hours for a non mechanic like me I thought that was pretty good .

[Snail Style]

Most likely signs of the driveshaft getting close to dieing. Should just get ahead of it and replace the driveshaft and spline hub before it craps out and leaves you stranded.

[Umai Naa!!]

t5 transporter stub shaft | eBay

Likely culprit.

[Sunny43.5]

Thanks Umai I had that thought it might be the shaft I can get one from the UK $238 plus $278 freight hmmm or local supplier in Sydney for $350 plus $30 freight I will check VW tomorrow just for comparison . Out of interest does the gear box need to be remove or dismantled or does the offending shaft come out separately I have vague memory of unbolting the shaft when I did the clutch 8 months ago but not 100% clear . Thanks

[Umai Naa!!]

Once you slip the driveshaft off, there will be a bolt in the centre of the stub shaft. Undo that, and the stub shaft will come out. You'll need to dump the gearbox oil first.

[Sunny43.5]

I take it the whole thing back to the box is what needs to be replaced I see the big nut at the centre of the rotor so no problems .Just a question I remembered that when I did the clutch the shaft was unbolted from just outside the box is there another part that goes back inside that could be the problem ? or have I got it wrong somewhere .

[Umai Naa!!]

Item #20 is a repair kit. Comes with everything you need, including the stub shaft.

Item #30 is the bolt I'm talking about. Once you've got the driveshaft out (not in the image), you'll see the bolt inside the stub shaft.

[Sunny43.5]

Okay so the actual part required is not the big long one with the CV joints its the one that is at the gearbox end as I remembered once you unbolt the drive shaft with CV joints there is another remaining part that is at the edge of the gear box casing is this where the nut is and once removed the offending part is then replaced sorry for so many questions .

[Snail Style]

Nah mate, as in the picture above you need to replace part #20 as well as the driveshaft. There's no need to change the seal aslong as you don't damage it, and there is no need to drain the gearbox fluid.

Once you get the driveshaft out, you will need a long 6mm hex bit to get the bolt out for the stub shaft. Reason for replacing both the stub and driveshaft is that the new stub shaft has revised(improved?) splines and will not match to the old shaft.

[Golf Loon]

Yup. You won't loose the gearbox oil. Make sure you have the right tool to get right in there. Not the place to snap off an Allen key.


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