drive shaft popping out

thunder039

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Mar 16, 2011
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Bairnsdale,gippsland victoria
been having this reoccurring issue with the driver side drive shaft in our 04 forester. basically it keeps coming out.
have had it to a drive shaft specialist a few weeks ago to fix the issue, they installed a different clip hoping it would hold, unfortunately not as it came out again yesty so i am not very happy at all. I called back the place going in Wednesday, they said it will have to be machined to make a bigger groove so the clip can bite in better.
they said that they have only seen one other car model with the issues which was the Mitsubishi pajero from a few years back.

i was wondering if anyone has had or heard of the issue happening?
 
Gidday Thunder

Sounds like a defective part from new ... :(

You may well be far better off (and financially) just fitting a fully reconditioned shaft and CV joints, rather than mucking around trying to fix something that was wrong to start with ...

Last one/s we bought for the Camry and Roo1 only cost about $250 each, fitted.
 
thats what i was thinking ratbag but i will ask the place what is the cheapest option just want it fixed due to at the moment the only car we have is a borrowed corolla and the brumby haha
 
Ross, our mechanic, reckons that he cannot even strip, clean and re-boot one CV joint for the price of the reconditioned shaft with two CVs and new boots.

He also pointed out that the reconditioning is done in a factory production line, with new over-size balls, new cages, re-machined inner and outer races. He added that nothing he could do to a used CV/shaft could even come close to the end result of going down this track, and his result would end up being far more expensive for a lesser result.

You can see why we trust him and his judgement ... :cool:

Not only is he a good, honest bloke, but very reasonable prices and knowledgeable to boot :ebiggrin:
 
thanks ratbag, i will ask them about a new or reconditioned drive shaft on the Wednesday, and tell them that i want it done the cheapest way.
i would suspect that even a new drive shaft would be cheaper then getting the current one machined?
 
I bought a brand new CV (yes completely new not reco) from a CV specialist for $147 a few weeks ago. I fitted it myself which took 20-25mins. They charge $40 to fit it but I didn't bother with that. Get a new locking in while your at it.

Taz
 
I assume it's the front drive shaft? Sounds like it's the wrong drive shaft. As I recall, there is no locking pin in my MY'03 and I think the 04 is the same - I can check the manual tonight.
 
got the car back today from trembath in ballarat (highly recommend them)

they machined the end of the shaft so that the groove was more square so that the clip will hopefully bite in and not come off. did the work for free due to the what they did before not working and they couldn't guarantee that it would work this time, but we are hopeful that it will
 
Thats pretty good they did it for free. Not many places left who have the integrity to stand by their work! Lets hope it works or my advice would be a new or reco drive shaft assembly. Good luck mate, it must be pretty frustrating for you, esp with your engine probs! :(
 
it happened again :sadbanana:

i have been in tassie, on a two week camping trip and i noticed it on the 12th day

i was able to get the shaft back in but come out about 3 more times until i got home yesterday.

not sure what the next step is, the drive shafts are original so perhaps a new one might fix the issue?

i thought it could be the weight making the rear sag causing it to come out, but with the self levelling struts the rear didn't really change all that much so not sure why it has decided to stuff up again :shrug:
 
Mate thats a bugger :(:shake:

I reckon your only choice is a reco...its just not worth the cost in the long run, the aggro & the unreliability. I'd just bite the bullet & get it done properly once & for all.
 
aww thunder039, I hope your trip hasn't been too disrupted. Sux to have mechanical problems on a holiday :(
 
Just wondering if something in the rear suspension has shifted. Perhaps measure each side from the hub to diff. If one side is further from the diff than its meant to be, that might explain it popping out like that. You would have to measure pretty accurately as only a few mm could do it :shrug:

I hope it didnt spoil your trip...
 
It shouldn't move at all!! There should be 0% play in the cv with it in the vehicle properly!! I had issues.Herrington CVs out with the diff sitting on the ground with a fair but of play in the CVs..
 
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