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Old 20-01-12, 21:07
craigz_art craigz_art is offline
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T5 Post Icon driveshaft and sheared splines on gearbox

Model: 2006 T5 t30 2.5tdi Kombi

went to pull off from standing start heard a bang then felt a judder through the pedals a grinding judder came from the bottom of engine when I rev-ed up. tried all the gears but there was no drive.

I called the AA and had the privilege of giving them a £130, they came and said hello and offered to take me to the garage. This was when I wished I had joined them for £40 all those times I seen them at the services on the M1.

My Mechanic said to me it didn't look good which made me sad.... he had a look and said that the drive shaft is knackered on the offside and that the splines are all sheared on the gearbox.

we both thought the worst (not having experience with a T5) and assumed we needed a new gearbox and drive shaft... I checked all the sites I could online regarding the problem. I found two both which told me conflicting information that's why I have spent the time to write this, in hope that it helps someone..

The sheared splines on the gearbox is apparently a common fault with the T5 2.5tdi from 30k upwards (mine was 220k).

You can replace just the sheared splines! the parts are called the ‘stubb shaft splines’ they are an exchange component according to the Internet they have a bolt down the centre, which is a 6mm allen head bolt you will need a long shaft allen key to undo it. Make sure they are greased!

the part can be got from VW themselves or where I got mine from TPS (http://www.thetradepartsspecialists.co.uk/) at a guess about £140ish along with the drive shaft £200ish

Once my van was fixed it drove like a dream and looking back on it. I did have a hard take up when pulling away through the clutch which I didnt see as abnormal at the time but it was obviously a play on the stubb spline shaft.

Tip: Erwin online 5 euros for an hour, download the pdf’s very handy!
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  #2  
Old 20-01-12, 23:42
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JIMMYJAMES JIMMYJAMES is offline
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Default Re: driveshaft and sheared splines on gearbox

Common fault indeed bud, hope you get it sorted
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Old 20-01-12, 23:49
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WickedVanz WickedVanz is offline
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Default Re: driveshaft and sheared splines on gearbox

Been covered many times on here, very common problem, and worth noting when buying a van there should be no slack on drive take up.....

http://i42.tinypic.com/2dheh54.jpg
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Old 21-01-12, 00:08
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Vanjak Vanjak is offline
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T5 Post Icon Re: driveshaft and sheared splines on gearbox

1.9, 05 plate & 72k miles. Pulled away from junction last night and suddenly zilch gears or drive. Relay, (thanks insurance) home tea & bed....deal with later ~ well it was 3am .
Garage now investigating "gearbox problem" and spending whole weekend typing up estimate !!
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Old 21-01-12, 00:10
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WickedVanz WickedVanz is offline
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Default Re: driveshaft and sheared splines on gearbox

Another driveshaft and input shaft failure!!

http://i42.tinypic.com/2dheh54.jpg
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Old 21-01-12, 09:56
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Bobbster Bobbster is offline
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Default Re: driveshaft and sheared splines on gearbox

Has anyone done a thread on this with pictures? Can it be avoided with preventative maintenance? I do remember reading a post I think where VW did not grease these/one of the splines on assembly is that correct?

Just thought if it is a common occurrence it would be handy to have a thread with pictures as sds law dictates it will always happen at the worst possible time!!!
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Old 21-01-12, 17:20
Pikalo Pikalo is offline
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Default Re: driveshaft and sheared splines on gearbox

If its a common problem, no grease when first installed. Shouldn't VW be held responsible for being Fu&£ing stupid, lazy and cheap! Seeing as oil and other lubes are so important in keeping these vans out of garages. Probably same old cornflakes, money making
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Old 22-01-12, 23:00
Damogr1 Damogr1 is offline
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Default Re: driveshaft and sheared splines on gearbox

Hi Guys


My 2008 2.5 130bhp 6speed manual has a wine coming from the gear box @120,000km has anyone seen or heard of the promlem.
Am i looking at a box recon or is it a simple fix???
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  #9  
Old 25-01-12, 23:10
Hair bear Hair bear is offline
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Default Re: driveshaft and sheared splines on gearbox

Interesting thread...
We run a fleet of T5s, with very different results.
We have two 07reg swb 80hp 5spd T5s, one with 250k on it, the other 300k so far, and no transmission problems of any kind. Not even a clutch.
One 59reg lwb 130hp 6spd T5 60k has so far screwed 2 drive shafts. Awful machine. Drives like a wet sponge!
Two 60reg lwb 140hp 6spd T5.1 each at around 65k have both done one shaft each, and one has slack in the drive suggesting a second is on it's way.
One 60reg lwb 140hp 6spd T5.1 65k, No hint of a problem yet.
Does it depend on who was on the assembly line at the time? What happens to all the broken bits of spline?

Rob.
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Old 25-01-12, 23:18
Austin man Austin man is offline
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Default Re: driveshaft and sheared splines on gearbox

mine makes a thud if I let the clutch up quick should I be planning a bit of preventative maintainance ie changing the cv join at the gearbox end or is the problem far greater than that van has 190k on it
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