Drive/prop shaft popped out (again) 2zz mr2

rokz_2005 · July 25, 2016, 23:45

Hi All,

I had another thread in the past regarding the drive shaft popping out Of the inner join shaft housing.

It was originally diagnosed that the swap mount was not used which meant that the engine was slightly offset allowing too much play in the shaft.

I've replaced the mount and stuck the driveshaft back in. Last night i floored the car and bang, it popped out again. The last shaft hit the engine so hard it broke pieces clean off and i needed to rebuild the whole underside (costly).
It doesnt look like the block is damaged but I need to inspect it closer.

I'm just wondering if someone would be able to advise me what went wrong.

My suspicion -
The car is lowered, maybe it wasnt done properly
The other two engine mount needs to be further loosed and move tue engine then retighten

Any specialists in London I can show the car to. I should be able to pop the shaft back into the housing.

I look forward to seeing what you guys think.

cabbydave · July 26, 2016, 06:42

What have you used on the joint? Have you used the genuine cv boot and steel clip to hold it on?

rokz_2005 · July 26, 2016, 12:59

Quote from: "cabbydave"What have you used on the joint? Have you used the genuine cv boot and steel clip to hold it on?

I can't remember now but I either had them metal radiator hose clips or plastic ties.

Assuming the fastener from the boot came off, would that cause the shaft to pop?

I'm hoping it's not anything major

cabbydave · July 26, 2016, 14:38

That's why they are popping you need the genuine cv boot and clip to hold it on

stupink · July 26, 2016, 15:18

I doubt very much the boot coming off would cause any immediate issue... not until all grease has flung all out everywhere..

do you have any photo's? i'm not sure what a 2zz converted car would look like in this area..

JoeCool · July 26, 2016, 19:30

Quote from: "stupink"I doubt very much the boot coming off would cause any immediate issue... not until all grease has flung all out everywhere..

do you have any photo's? i'm not sure what a 2zz converted car would look like in this area..

I mean, it should look exactly the same. You use the 1ZZ drive shafts and the Diff housing should line up exactly where the old one was. The gearbox location is the same.

I think rokz's engine must be askew, it's the only explanation.

rokz_2005 · July 26, 2016, 21:50

I'll try and get some pictures this weekend. To be honest the difference in position would so small (if any) to be able to see anything wrong in the picture.

Im thinking when I did the engine mount swap, the engine did not move enough.

I didnt notice the boot coming off prior to this incident. Ive been working in the engine bay recently.

The cv boot was the one the car came with. Looked durable so I assume its original. The only theing would be that the correct clip was not used but the boot was fitted good.

Is there any way to measure how far the outer shift should sit within the inner shaf housing? Or does anyone know the length?

jonbill · July 26, 2016, 22:21

Just to clarify, which driveshaft is coming out, and where?

secla · July 26, 2016, 23:29

The boot coming off is not going to cause the driveshaft to pop out, im assuming you mean the actual shaft is popping out of the cv cup ?
The only reason its popping is because its overstretched so either the engines in the incorrect position or the shaft you are using is to short. Either this or the snap ring that holds them in isnt up to the job anymore !

rokz_2005 · July 28, 2016, 10:16

Quote from: "secla"The boot coming off is not going to cause the driveshaft to pop out, I'm assuming you mean the actual shaft is popping out of the cv cup ?
The only reason its popping is because its overstretched so either the engines in the incorrect position or the shaft you are using is to short. Either this or the snap ring that holds them in isnt up to the job anymore !

It's the driver side (longer piece) I dont know the correct terms for it but what you're describing sounds right. It was overstretched previously as I didnt have the swap mount installed. The mount should have rectified?? The shaft is the right one as this came with the car.

The are no clips holding the driveshaft together at tuhe joint. Say I took the driveshaft out and the boot off, I could simply slide the shaft out of the housing.

gazza1286 · July 28, 2016, 14:00

Surely if the engine /gearbox is too far left or right both engine mounts would need replacing - one 'longer' and one'shorter' to allow the engine to shuffle over...

jonbill · July 28, 2016, 15:49

I think a pic would be very useful at this point!

cabbydave · July 28, 2016, 20:34

What gearbox mounts are on the car

rokz_2005 · July 29, 2016, 21:39

I dont have too much technical knowledge so Ill put some pictures up tomorrow.

Maybe we can get to the bottom of it.

rokz_2005 · July 30, 2016, 14:23

Its way worse than I thought. problem on tue rear middle engine mount. Take a look at tue picture.

m https://flic.kr/p/JHb2Jd m
m https://flic.kr/p/KAQPDj m
m https://flic.kr/p/KDH4iF m
The bolts have broken out of the gearbox and the engine has clearly moved to the left allowing the drive shaft to slip out.
Could it be that the third mount was moving the engine to the left still?...

I think the repair will now include a new gearbox n drive shaft? Or does anyone want to buy it off me. I have such bad luck with cars :,(

Carolyn · July 30, 2016, 14:34

Where are you located? I'd like to take a look...

stupink · July 30, 2016, 14:38

Hard to tell from the picture but looks like half the cv joint is still on the shaft. I think it could have been either way. Mount went loading up cv. Or cv seizedlocked and the LSD couldn't disperse that much energy twisting the box and breaking mount. Get the box welded and re-tapped. New shaft and try again.

gazza1286 · July 30, 2016, 15:02

The o/s and/or n/s engine mounts must be fitted incorrectly resulting in the rear gearbox mount being misaligned. At rest the mounting bracket should line up with the gearbox fixture which it doesn't. When last bolted up that mount would have been under a significant amount of stress it's not surprising it failed. That failure allowed the rear of the gearbox to move to the offside resulting in the shaft popping out.

Anonymous · July 30, 2016, 15:28

Knowing the amounts of bolts on that mount I would say its been loose and the engine been twisting enough to pop the shaft

rokz_2005 · July 30, 2016, 16:02

I think gazza is right.

I remember the the mechanic had to re align the now broken mount after I installed the swap mount. Whih was not done by the conversion garage. So it makes sense that the engine was always under tension and being pulled to the left.

If i was to get this fixed, would it be recommended I have the gearbox welded and tapped (would it be structurally strong?), newmounts and new drive shaft?

Any good garages in east london/essex area?

Carolyn · July 30, 2016, 16:44

If the engine has been tweaked around that much I should think all the mounts are damaged and need inspecting/replacing.

rokz_2005 · July 30, 2016, 18:15

I was thinking that too.

If the weld and tap becomes complicated, I would be able to weld the mount bracket onto the gearbox right? That part of the mount doesnt have any bushings or anything.

Carolyn · July 30, 2016, 18:38

That is the baddest bad idea I've heard in a while. Gearbox: Ally. Engine mount: steel. They don't weld.

It sounds as though this engine conversion was pretty badly bodged. I know you didn't do it, but bodged it was. If it's going to get fixed, please find someone who can do it properly. Basically all engine mounts off and do the install all over again, this time with everything properly lined up.

You can source decent used mounts and driveshafts, with a bit of shopping around.

If you want the car to be fun to drive and have some value it needs to be done correctly.

rokz_2005 · July 30, 2016, 20:01

Right you are.

Can I get some recommended garages in the london area.

The inly person i can think of is patrick (headcase) but he's quite far out.

Carolyn · July 30, 2016, 20:12

I'm afraid I don't know garages close to you. I'm sure some of our members can make suggestions. You might have to be prepared to get her towed some distance to get the expertise you need.

There are a few very competent members who have done these conversions who might be able to assist.