Potential Fiat gearbox screw up

The 'retaining clip' is just a snap ring. For it to come of the shaft (even if broken) would require the shaft to be pulled far enough out to allow the end of the shaft to completely disengage with the internal splines in the gearbox. And given you only pulled it out 1/2", the clip should still be where it's meant to be.

Bah. What is it with the nightmare of Fiats eh? I am seriously thinking of ditching my partners 60S and having 2 Skodas :o) They're great.

Although most of my troubles seem to be on the cooling end. The engine, at

60k it still seamingly ok.

Good luck on the gearbox - way beyond my level of understanding.

In message , M Cuthill writes

I do hope you're right. Can you fill me in on what a snap ring is please. Were talking just a wire ring right? (googling right now) You're suggesting it'll stay on the shaft even as its withdrawn through the splines on the diff output gear, and snap back into place when the shaft is pushed back in?

Fingers well crossed.

Cheers

In message , Steven Briggs writes

Now I'm applying cold hard engineering logic to this. Which is a little dangerous on something designed by Italians ;-)

1) If the retainer was meant to be positive and thus a circlip or similar, there's no way the shaft would be able to be pulled out. I don't know how much axial force I applied while jacking up the hub to get the new sus arm in, but unrestrained it naturally drifted outwards. The sound of dripping oil at this point was a definite "oh f***" moment! (

that's right, but some drive shafts don't have them, as the force of the suspension pushing against the shaft holds in it place.

some shafts just "flop" out and if your not quick enough you loose gearbox oil others are a right pig to get out, you have to use a pry bar between the inner joint and the box to force it out.

Not according to the full Fiat manual it doesn't. The 2001 JTD use the same as the std 1.4 Fiat. There is a circlip at the gearbox end but it is inside the inner CV housing. Thes are sods to remove normally and there is no problem unless you slide hammered it out of the box. Even if it was broken it could not enter the gearbox, only interfere with the inner CV joint. If you are really worried, I could send you the manual bits somehow I guess. But in my opinion ( I am a 'proper' Mechanical Engineer) there is nothing to worry about. Hope this helps Dave

Thanks everyone. Panic & paranoia now over, everything seems to OK.

Now just quick MOT retest and job's a good 'un.