Loud BANG then...

[Tailwind]

Thanks 78F350. I think mine might have the same. Did not hear from the shop yesterday, keeping my fingers crossed.

[m332is]

I had the rear wheel bearings replaced and the mechanic didn't torque the axel bolts properly (actually think he barely hand tightened them) and I dropped an axel. Same noise, same result.

[The Radium King]

mechanic had to remove transmission to r&r clutch, etc.

requires disconnecting axles from flanges at transmission.

when reinstalling, the bolts that fasten the axles to the transmission flanges have to pass through the inner cv joints.

in the process of passing through the cv they pick up grease and don't hold torque.

as you drive they slowly back off and fall out until only one or two are left.

remaining bolts shear as they are not strong enough to manage the torque transfer from transmission to axle.

axle lets go and bangs around underside of car making lots of noise and doing damage.

flange on that side now spins freely as not connected to axle any more.

given you have an open differential, no load on one side means no drive to the other.

no matter what gear you choose, nothing happens.

[Tailwind]

Thanks Radium King.
That explains a lot.
The clutch job was done 2 years ago, so plenty of time to work loose.
I think I dodged underside damage, as it happened as I was slowing in approach to an intersection, doing about 30mph, then started to accelerate. After the bang, I must have only traveled less than 20 feet.

[DWBOX2000]

Would the axle bolts give any warning? Would it clunk around a bit prior to popping off.
Is it a big fix?

[Gilles]

Originally Posted by DWBOX2000

Would the axle bolts give any warning? Would it clunk around a bit prior to popping off.
Is it a big fix?

DWBOX,
This hapen to me twice in two different cars and just re-installed and tighten the bolts (one time on the spot) as the bolts remained attached to the CV joint, the other time had to towed home as the remaining bolts sheared after a few got loose and fell into the ground.

[Jager]

Driver's side axle... Don't asks me how I know.

[mikesz]

Same thing happened to me was my right inner cv joint. I have a tip and was noticing a bang when i put it in reverse, then as i was driving and when the trans downshifted.

[Tailwind]

Just heard from the shop. "broken axle". The inner CV exploded. He said the CV was just spinning around with its components loose inside, so may have damaged the spline. He is going to see if his machine shop can repair the axle. He'll let me know later if the axle needs replacing.

[maytag]

Originally Posted by Tailwind

Just heard from the shop. "broken axle". The inner CV exploded. He said the CV was just spinning around with its components loose inside, so may have damaged the spline. He is going to see if his machine shop can repair the axle. He'll let me know later if the axle needs replacing.

good. that's the least painful repair I could think of for your symptoms. :dance:

[Gilles]

Originally Posted by Tailwind

Just heard from the shop. "broken axle". The inner CV exploded. He said the CV was just spinning around with its components loose inside, so may have damaged the spline. He is going to see if his machine shop can repair the axle. He'll let me know later if the axle needs replacing.

Tailwind,
Instead of repairing the axle, perhaps be way cheaper to get a used axle from Woody..

[Tailwind]

+1 maytag
Gilles, I've owned the car a week and a half, and the shop has had it longer than I.
I'm learning a lot about the 986, and am looking forward to some mods. Dave (my trusted mechanic) has a good reputation, and I don't want to second guess him. I could have changed the axle if I had seen this coming, knowing what I know now, thanks to members' input. Anyway, the case isn't closed, because Dave first said "we need to find an axle". I still need to hear back on the status.
Can you point me to Woody? If Dave says the shop cannot repair the axle, I can suggest it, thank you.
More to come...

[particlewave]

Woody's Parts, LLC: 512-925-9171, Bastrop, TX.

[The Radium King]

i would advise against buying a non-oem axle. look to repairing your own or buying a used one from woody and rebuilding if necessary.

the damage to the splines may be par for the course; when i serviced my axle, i found that the inner cv had worked the axle a bit, marred the splines, and was quite difficult to get off. axle was still well reusable however, and the actual cv, boot, bands, are inexpensive.

lesson - keep an eye on your cv boots; clean and treat them annually.

[jaykay]

[QUOTE lesson - keep an eye on your cv boots; clean and treat them annually.[/QUOTE]

This is a great idea.......probably the most critical rubber to address on the car........what do use to treat them? One would want to unduly degrade them boot with something that's not compatible.

Loosing the boots means a lot of work and expense

[Tailwind]

Just heard from Dave. No issue with the splines. Dave said that if the axle could not be rebuilt, they would have returned it.
They rebuilt the assembly with a Kolbenscmidt CV joint and it will be ready today.
I know Kolbenschmidt made pistons, but I can't find any citations about CV Joints.

[Gilles]

Tailwind,

You meant Kolbenschmidt in Shanghai...?

Sorry, could not resist...

[Tailwind]

They sublet the rebuild of the axle replacing the inner CV. Runs great and tracks nicely, but now that I've had a chance to drive it more...man it rides like a buckboard. With 99K, I'm gonna do the shocks.
Since the nose has a lot of scoring/pitting, I want to get the nose painted (I have the Aero option on the car). I queried the mechanic about a nearby body shop, and he said "you have an old car. You should just drive it for a couple of months and see". The car has a few small dents and dings, but I won't address those right now, but don't want to drive it with the nose looking like that. It's a Porsche pride thing
The other "major" issue is there is a big hole in the outer driver side bolster. I'm looking at options.

Detail of nose lightened to show damage...