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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old February 4th, 2011, 20:39   #1
rallyruss
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Default Add another BHW tesioner failure

To all you naysayers.... Come on! Another one.....

Finally had a chance to dig into my wife's passat to get down to actually inspect where that noise and vibration is coming from. As I dropped the pan the smaller chunk o bad design clunked into the pan. Its been this way for a while based on the wear.

118K miles on the car and it actually ran decent like this.

Listen to Oil hammer, Mo Golf, Runonbeer and the rest who do these or know about it.

VWOA set us up good.
http://pics.tdiclub.com/data/567/Photo0131.jpg

This is a heck of a fun job
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Old February 4th, 2011, 20:43   #2
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Better to catch it now than 30 seconds after the chain breaks.
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Old February 4th, 2011, 22:21   #3
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Better to catch it now than 30 seconds after the chain breaks.
Thats for sure.

There is a reason why we have been avoiding using this car for any kind of distance away from home.

This thing is a glorified bike chain.....

will start reassembly tomorrow. So far so good.
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Old February 5th, 2011, 05:39   #4
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Put some J-B Weld on there, slap it back on.
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Old February 5th, 2011, 07:51   #5
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Don't forget the duct tape too!
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Old February 5th, 2011, 11:46   #6
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what a surprise, it broke right along the "perforation"
' cast into it.
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Old February 5th, 2011, 12:31   #7
rallyruss
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My wife wants to mail the parts back to VWOA with a note...

So we baked the gear this morning. My fluke temp probe only registered 350deg F although the oven was at 400+
Wish I had an infrared heat gun at home.

The gear went on no problem. It makes me a little nervous possibly heating a gear above 375 deg F.
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Old February 5th, 2011, 13:23   #8
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Quote:
Originally Posted by rallyruss View Post
My wife wants to mail the parts back to VWOA with a note...

So we baked the gear this morning. My fluke temp probe only registered 350deg F although the oven was at 400+
Wish I had an infrared heat gun at home.

The gear went on no problem. It makes me a little nervous possibly heating a gear above 375 deg F.
Looks like you would have to get above 1154 degrees centigrade before anything happened to the gear's properties:

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Old February 5th, 2011, 13:54   #9
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interesting.

when fitting gears and couplings on our equipment at work they normally recommend staying below 400deg F to not change any of the heat treatment properties.
Well its happily on and I'm working on fitting the new balance shaft now.
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Old February 5th, 2011, 15:40   #10
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Quote:
Originally Posted by rallyruss View Post
interesting.

when fitting gears and couplings on our equipment at work they normally recommend staying below 400deg F to not change any of the heat treatment properties.
Well its happily on and I'm working on fitting the new balance shaft now.
Actually, at 1154 C it turns liquid. Depending on the way steel is hardened, and the carbon content, things can happen to lower temperatures. But in the low hundreds, not much can happen other than some coloring.
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Old February 6th, 2011, 21:11   #11
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Well shes a runnin!

I fired it up tonight. Its still on stands for other unrelated repairs but the engine runs great. Feels smoother to me but a real road test is in order soon.

I really took my time but it really was not that bad now that its all done.

This is NOT a job for a rookie shade tree mechanics. Only experienced shade tree mechanics
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Old February 6th, 2011, 21:22   #12
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Quote:
Originally Posted by rallyruss View Post
Well shes a runnin!

I fired it up tonight. Its still on stands for other unrelated repairs but the engine runs great. Feels smoother to me but a real road test is in order soon.

I really took my time but it really was not that bad now that its all done.

This is NOT a job for a rookie shade tree mechanics. Only experienced shade tree mechanics
Great, nice job. Did you change out your motor mounts or were they not leaking?
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Old February 6th, 2011, 23:41   #13
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Quote:
Originally Posted by aja8888 View Post
Actually, at 1154 C it turns liquid. Depending on the way steel is hardened, and the carbon content, things can happen to lower temperatures. But in the low hundreds, not much can happen other than some coloring.
IIRC the coating on the gear is the reason for the lower temp. or does the intermediate gear only have the coating?
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Old February 7th, 2011, 03:30   #14
thundershorts
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i used my forge and cones to raise the temp.less than two minutes was enough to melt the 350 degree cone and i had no bluing. gear is made of pressure cast steel.
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Old February 7th, 2011, 03:56   #15
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Quote:
Originally Posted by greengeeker View Post
IIRC the coating on the gear is the reason for the lower temp. or does the intermediate gear only have the coating?
Coating is only on the intermediate gear.
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