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-   -   BHW Balance Shaft Module replacement (http://forums.tdiclub.com/showthread.php?t=233651)

leicaman January 21st, 2009 19:39

Did you examine the chain tensioner? That baby usually really gets worn according to what MoGolf discovered on his unit.

oilhammer January 22nd, 2009 04:17

They all have some normal grooves in them from the chain, but it is when stuff suddenly BREAKS that causes all the damage.

It's like this Escort we just had in here. Owner was driving one day, running fine. Ran to the store, came out 10 minutes later, started the engine, and a valve seat fell out of the head. No warning. No noise beforehand. Just instant catastrophe. Of course the Escort 1.9L engine is known for this, just like we now know the BHW engine is known for chain/tensioner failure.

That is why I stand by my thinking that ALL of these engines NEED this upgrade done, and looking at still-intact parts won't really tell you much of anything. And there still seems to be some gray areas on noise-to-failure, as some engines have been REALLY noisy but still intact at 100k+ miles, and others have broken and worn holes through the engine with (as the owners state) no warning. The one guy did not even know anything was wrong until he went to change the oil and noticed a chunk broke out of the oil pan/chain cover! :eek: My gut instinct is that the engine almost had to be making some noise beforehand, but who knows???

senez January 22nd, 2009 04:32

Quote:

Originally Posted by outthere
My BS transplant is complete thanx to www.4induktion.com in Hanover, MD.

Great guys who communicate well, what a nice change from typical dealership service where the guy answering the phone has no idea who you are or when you can pick up your car.

The old module w/ chain drive looked fine, no visible wear. If anyone is interested in a good deal on a chain and module feel free to PM me. The car feels and rides better than new.

If you are on the East Coast induktion may be an option to consider- maybe 2-3 miles to Amtrak/BWI so easy to drop the car and get a cab/bike ride to the train/plane/rental car. I have about 550 miles left on my 100k mile warranty so driving to St. Louis didnt seem to be a good use of miles/time.

Again many thanks to all who figured this out and shared the info.

Any word on the price they did the job for?

Skivvies January 22nd, 2009 06:50

I finally got most of the parts in yesterday from the dealer minus the crank gear and some bolts. I ordered them last month just before World Impex put together their kit. When I mentioned the price difference at the dealer, they were nice enough to knock 10% off my order! This dealer (VW of Orange Park) has been very nice to deal with, at least their parts department, and have put "car down" rushes on items so they all arrive close to the same time. Time to start opening up the wagon.

oilhammer January 22nd, 2009 06:58

You are missing the same parts I am I bet to complete the last 4 sets I have. The 4 little bolts that hold the small gear to the BS module and the big gear that goes on the crank.

I just called, and there are currently 61 of those little bolts on backorder and the 'estimated delivery date' at the New Jersey warehouse is 3-17-09 :rolleyes:

maktas January 22nd, 2009 07:46

Quote:

Originally Posted by oilhammer
You are missing the same parts I am I bet to complete the last 4 sets I have. The 4 little bolts that hold the small gear to the BS module and the big gear that goes on the crank.

I just called, and there are currently 61 of those little bolts on backorder and the 'estimated delivery date' at the New Jersey warehouse is 3-17-09 :rolleyes:

If you can find the specs on the bolt (size, length, pitch) why can't you find an alternative?

oilhammer January 22nd, 2009 08:42

Quote:

Originally Posted by maktas
If you can find the specs on the bolt (size, length, pitch) why can't you find an alternative?

Posted that info in this thread:

http://forums.tdiclub.com/showthread...62#post2429562

Knock yourself out, I have had no luck. Fairly specialized bolt, not a hardware store item. :(

DickSilver January 22nd, 2009 11:50

As of this afternoon, Impex has gotten the missing VW bolt, and has my kit in a box waiting for UPS pick up. So as of next week, I will be able to schedule the job with Fast Enough Performance. Nearly there!!

cspeter8 January 22nd, 2009 17:11

The order I placed with World Impex on Jan 8 also shipped today - I just got the UPS email with the tracking number. Still trying to decide on a shop to do the work... This morning I spoke with Franko the owner at Prospect Foreign Car Center - I've heard only positive stuff from customers at the shop on the several occasions I've stopped in to look around, and found only positive reviews for them on the net. They have abot 20 established customers with Volkswagens, have done a number of timing belts on VW, have worked with removing crankshaft sprokets on a volvo (but never a VW) so they say they already have that sproket puller with the /3 and /5 jaws - one of the more expensive sst's on the list. They have been there for 20 years at the same location. Franco says he doesn't know how much it will cost me labor-wise because he has never done this job before. That's reasonable, right? But it does make me uneasy - ideally a mechanic would know because they did it before, but I can't have everything. I asked for references of some other folks who had similar work done, and he wasn't comfortable doing that. Sounded like he never gave out references for customers before so he didn't want to start now - the good reputation he has, without advertising, he says was all he needed to grow his business (my loose paraphrase).

I like the location of this place ... it is on the bus line I take to get to work, about 20 minutes drive from my house. I could drop the car off and easily pedal back home on my bicycle, while the wife is away for a week visiting the inlaws next month... Should I?

Have any mechanics ever done a phone consultatoin with OilHammer about this procedure, like if a surprise comes up? I was wondering if the willingness to consult with the expert should be a criteria in selecting a shop to do this.

oilhammer January 22nd, 2009 17:24

I get so many phone calls a day I have a tough time getting my work done. However I try and help everyone I can, but honestly the writeup that MOGolf and I did (well, HE did..I just worked on the car) has pretty much all the information in it. It is pretty comprehensive.

I am still sticking with 8 hours labor, and this is a pretty fair number. This is based simply on book time for the water pump and oil pump. I think the water pump/timing belt job is 4.6, and the oil pump is 2.9. Then add in the stuff dealing with the crank gear and that is where I get 8 hours.

Keep in mind I had done 7 chain modules before I did the first gear module install, if someone is doing this from scratch the first time through I would fully expect it to take over 8 hours to do correctly.

leicaman January 23rd, 2009 01:13

Here is the technical bulletin that Oilhammer discovered that got everybody in B5.5 TDI land down the geared path and away from the chains of motor mayhem. I cleaned up one ugly original and added one of Oilhammer's photos to help illustrate it. There is also the parts list he provided.

http://pics.tdiclub.com/data/500/BHW...pGear_TPI1.pdf

KALaBenne January 23rd, 2009 10:58

Thanks oilhammer and leicaman!

Tom_B January 23rd, 2009 11:42

Nice job leicaman, that's very helpful and informative. Just a suggestion: One never knows how your document will get distributed or used. You may wish to consider re-inserting the original "page 4 of 4" to keep the original document intact, then have an additional edited page with your photo and somehow clearly state/distinguish that your photo and edits are not part of the original technical bulletin. I'm not a lawyer or implying anything legal, but I have experienced unintended consequences with documents. Thanks again all.



(We're at 78k miles and keeping our fingers crossed to 100k, no obvious noise yet.)

leicaman January 23rd, 2009 11:47

Thanks for your suggestion. Here is the document in its original form for pages 1-4. Page 5 is the separate parts list. Page 6 features photo showing both types of balance shaft modules side by side along with gears and bolts via oilhammer.

The other doc has been purged and the below is the only one now available.

http://pics.tdiclub.com/data/500/BHW...pGear_TPI1.pdf

blaz January 25th, 2009 04:42

Quote:

Originally Posted by leicaman
Thanks for your suggestion. Here is the document in its original form for pages 1-4. Page 5 is the separate parts list. Page 6 features photo showing both types of balance shaft modules side by side along with gears and bolts via oilhammer.

The other doc has been purged and the below is the only one now available.

http://pics.tdiclub.com/data/500/BHW...pGear_TPI1.pdf

A suggestion: If MOGolf editted his original post in this thread to include this link, all the relevant info will be in one place...


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