Broke something in my drive line.

[HAMMER DOWN]

 I posted back in Nov. in "Gabe's leaving Hooray meet". That my GT just broke something in the drive train. Sounds like I strip some splines some where.  The sound is coming from the back of the transaxle. This what happen, after 5000 mile on my STi 6 speed swap. http://legacygt.com/forums/showthread.php?t=61199 Something let go. On my way to work. I stop at my 3rd. stop sign. A mile from my house. 1st. gear was fine, but into 2nd. It hold for a sec. Then a noise came from the tail shaft. Something between a grind & a clatter. Pulled over & look under the car. Didn't see nothing broke or leaking. Drove it back home. On the way home it drove fine as long as you didn't give it to much gas.
 
  When I tried to drive it  up on my car ramps. The car would hit the bottom of the ramp and stop. Something is slipping and no power is going to the rear drive shaft. Then I back-up & get a running start the ramps. Got half way up, started to slip and the car coasted back down the ramps.  So I back-up again, this time I put the your DCCD controller in lock. Got it half way again, started slipping. Stop the car on the ramps, pulled the E-brake. Thinking I must not have enough throttle input to lock up the DCCD. I let the clutch out. Started giving it more throttle until I felt the DCCD lock in & the car start pulling. Let the E-brake off and up the ramps I went with no noise from the tail shaft area. I took the transaxle tail shaft apart. All the gears look good that drive the tail shaft. Drive shaft looks good too. The gear oil as fine metal  shaving in it. And the magnet on the oil pick-up was covered, about 1\4" thick. So I pull the DCCD out. Took it apart & clutches are the only thing that shows wear, especially the rear. I get a ~1 Ohms reading from the coil so that's good. I order a new DCCD. Because to me, it's the only thing that make sense. When you have power to the front & not the back.
 
 After talking to Jeff, he built my DCCD controller. http://www.dccdpro.com/ Him & his friend Iain (best swap guy in Canada). Said check out the rear end & the half shafts. So before I install the new DCCD. Why'll the cars in the air. I dropping the rear end out. 1st. sign something was wrong. When I went to remove the half shafts. I was able
to pull them out with my hands. That's not good. What I found, just the driver's side (DS) half shaft was damage. About 1\8" of spline was chewed up. But that doesn't expain the noise I heard by the shifter. This is what I think what happen. I didn't get the half shaft in all the way when I 1st. did the swap. The cold weather didn't let the boot act like a spring and keep the half shafts in place. The DS half shaft work it's why out. Making the DCCD work harder to keep the car moving. Until the clutches, to the rear output shaft wore down enough to make the clutch pack chatter & slip. So sense I got the new DCCD at wholesale price. I installed it. Cleaned up the splines with a file on the half shaft. Pulled & took apart the rear diff. To cleared & inspect it for damage. None found, put it all back together. And the car work perfectly.

The front half shaft pop right in with a quick push with your hands. Did the some with the rear. so I thought it was in right.  The rear has a metal dust sheild, & the front doesn't. So the rear looked like it was in all the way. But this time I used a 3ft. pry bar to pop the rear shafts in. And rechecked the front, which was ok.

  Does anyone know the min. thickest of the DCCD clutches? I like to check it out, because if they are in spec. I going to try to sell it. I did want to take a chance with the old one with out knowing if the clutches are in spec. So I install the new one.

Mike