Transfer Case Issues! What A Pia

[groonsnout]

Here's an odd one..

I was getting some very bad vibrations/noises from the driveline of my S1 RS4 Auto (stock) and after a quick trip to my mechanic, they told me that the small drive shaft that joins the transfer case to the front gearbox (the one you remove for 2wd) was shot. Apparently the uni's were completely gone on it. He ordered in a GTR shaft as the measurements were the same, but upon installation the shaft was whipping under power like an unmanned garden hose! A short drive made certain that this wasn't the solution..

So here are my questions!

Is the GTR Shaft (not sure if 32 or 33) interchangeable with the stagea? He said it's thicker (40 vs 32mm) but the same length. And if not, where would be the best place to get a S1 stagea one?

Would it be the transfer case or the front box making the shaft whip like a snake? It really moves around and he is concerned it's the transfer case, but he said even in the high power GTR's he builds, he's never seen a transfer case go like that.

I've tried to search this, but it seems that this part of the driveline is normally pretty solid.. which worries me somewhat..

Help! These guys are Skyline guru's but new to stags.

Cheers,

michael

PS: I got them to fit a HKS silent power bolt on and metal cat while it's in there.. WTF not!

[Stinky Rooster]

The front driveshaft was the only thing that went on mine, and the GTR shaft slotted in like a bought one The only difference between the two (being that the S1 Stagea carries the GT4 driveline, not the GTR) was a step down in diameter about 2/3rds of the way along the stagea version.

Depending on what end of the driveshaft is whipping around, your problem is either going to be the output shaft bearing of the transfer case or the pinion shaft of the front diff. The front shaft uni's are not supposed to have any discernible "play" in them, so you should be able to isolate the problem by hand.

Just be glad that you got the shaft fixed before you snapped a uni, they almost always kill vital gearbox pieces (and in some cases clutch and bell housings hey Leshy?) when they break loose and start flapping about under the car.

[groonsnout]

The front driveshaft was the only thing that went on mine, and the GTR shaft slotted in like a bought one The only difference between the two (being that the S1 Stagea carries the GT4 driveline, not the GTR) was a step down in diameter about 2/3rds of the way along the stagea version.

Depending on what end of the driveshaft is whipping around, your problem is either going to be the output shaft bearing of the transfer case or the pinion shaft of the front diff. The front shaft uni's are not supposed to have any discernible "play" in them, so you should be able to isolate the problem by hand.

Just be glad that you got the shaft fixed before you snapped a uni, they almost always kill vital gearbox pieces (and in some cases clutch and bell housings hey Leshy?) when they break loose and start flapping about under the car.

Ew.. nasty! So do either of those situations normally consist of transfer case/front diff replacement?

[Stinky Rooster]

*shrug*

dunno. Personally, I would get new bearings and reco what was there, rather than take a risk with more imported parts, but I guess its up to you. There are plenty of donor parts cars in Aus if you want to go that way. (here in WA at least)

[groonsnout]

*shrug*

dunno. Personally, I would get new bearings and reco what was there, rather than take a risk with more imported parts, but I guess its up to you. There are plenty of donor parts cars in Aus if you want to go that way. (here in WA at least)

hmmn.. just got off the ph to the mechanic and relayed your thoughts - and he seemed to think the transfer case bearing was a chance. He said that normally when you drop the shaft out, you can unbolt 2 bolts, rotate it by hand and get to the other two, except he said that he couldn't turn it by hand, it was too stiff.. and the GTR shaft was actually fouling at the end of the transfer case (against a switch and a bracket that couldn't be bent back any more) His concern was that to change the bearing in the transfer case he had to drop the gearbox out of the car.. ($)

He also said that when he ran it with the shaft out the transfer case output was spinning true, but it was a bit hard to tell for sure. The bearing might have seized rather than collapsed, but there is no play with the new shaft in, but it goes spastic when spinning!!! ARGH!!!

<sigh>

[Stinky Rooster]

What we need now then, is some lovely member who has FAST onboard to post a hi res screenshot of the transfer case to get an idea how far the driven shaft goes into the clutch packs on the transfer case main shaft. It may be snapped inside.

[loymclure]

might have it by tomorrow if your keen to wait and no-one els posts.

[kidafa]

Hows this: