Failed CV Joints (DriveShaft)

DTYME83

Registered User
As some of you are probably aware the inner rear cv joint on the S1 is a massive weak spot. My car is currently in development with Track-Tek having a stronger more robust joint /shaft made up. As development unfolds I will update the thread.


Pictures below of what happens when it breaks and as some of you have noticed it effects the haldex

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DTYME83
 

DTYME83

Registered User
Spoke with Nick @ track-tek today and hopefully he should have something positive to tell by the end of the week fingers crossed
DTYME83
 

gingers3

Registered User

gingers3

Registered User
superchips are quoting 469 Nm from bluefin !
 

DTYME83

Registered User
Hi,

any news? Thanks

Caught up with Track-Tek yesterday and there may be potentially two options
Option 1 - Replace the CV joints using the current shafts
Option 2 - Replace the shafts and CV joints.
Hopefully i should have a solid answer today or at least in the next few days

DTYME83
 

DTYME83

Registered User
Caught up with Track-Tek today.
New shafts will be made this week and should be fitted to the car early next week.
If anyone is interested in please feel free to DM, as I sure there will be a minimum run on the manufacturing process.

DTYME83
 

Miguel Freitas

Registered User
Caught up with Track-Tek today.
New shafts will be made this week and should be fitted to the car early next week.
If anyone is interested in please feel free to DM, as I sure there will be a minimum run on the manufacturing process.

DTYME83

Can you have an estimation on the cost? They will do front and rear shafts?

Thanks
 

DTYME83

Registered User
Can you have an estimation on the cost? They will do front and rear shafts?

Thanks

As soon as I have an idea on cost I will update you, I relation to the fronts it was raised originally and at present they see no reason to do the front as they are pretty solid but I will however ask the question.

DTYME83
 

Miguel Freitas

Registered User
Hey... Back with some pics about the APR installation!

After some hard work here is the final and awsome result!!

PS - space is non existing!!!
 

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Miguel Freitas

Registered User
Any estimation on cost?

btw (off-topic): I did a test with my current setup on road from 0 - 62 mph and I could do 4.7s

Do you have any idea of avg values from other S1?

Thanks,
Miguel Freitas
 

DTYME83

Registered User
I should know cost by the end to beginning of next week, would you like me to put down for a set
 
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Miguel Freitas

Registered User
let me know when you have the cost and if not super high then I will want since the car is stupidly fast and torque is much higher!

I will go to dyno during this week or next week.
 

steflert

Registered User
Hi, I'm a newbie here. Your bad experience may worry most of us.
As you broke 2 CV joints, don't you think there might be a disfunction on your car ?
I mean that CV joints are usually designed for twice the maximum torque at the Wheel. And torque high values are reached during "accidental phase" when ESC system is working (wheel brake tightened). I was wondering if a disfunction of a sensor or a usual ESC activation in your utilization may explain... Anyway for a track use, I think more secure to switch off the ESC, specially with a remap.
 

DTYME83

Registered User
Hi, I'm a newbie here. Your bad experience may worry most of us.
As you broke 2 CV joints, don't you think there might be a disfunction on your car ?
I mean that CV joints are usually designed for twice the maximum torque at the Wheel. And torque high values are reached during "accidental phase" when ESC system is working (wheel brake tightened). I was wondering if a disfunction of a sensor or a usual ESC activation in your utilization may explain... Anyway for a track use, I think more secure to switch off the ESC, specially with a remap.


The rear shafts on the S1 are exceptionally small compared to the shafts on the A3/S3 and I am not the only one that has experienced this issue, so my take on it is that the car can't take the additional power.

DTYME83
 

steflert

Registered User
Sure you're right, must be a weakpoint of the car as it occured for several people. Now considering engine torque improvement (370Nm to 470Nm): with S1 full gearbox ratio in first gear, if i'm right max output torque may vary from 5000Nm to 6300Nm. Only half of this can be transfered to rear axle what means that each rear CV joint should see max 1250 Nm(stock) and 1575Nm(tuned), if part is well designed there mustn't be a problem. Situations where CV joint will see more is a recovery of grip after wheel slip OR when braking system is activated on one wheel by ESC what leads to a torque pic on the braked Wheel and hence full axle torque is transfered to the other CV joint. On my car, at only 6000 miles, a complaint has been raised by previous owner because rear brake discs were anormally used what make me think ESC is regularly activated.
My conclusion is: sure a tuned car will increase failure occurement but to reduce risk we may switch off the ESC for each track session or hard driving (not on straight road). Avoid 1st gear full acceleration specially on slippery roads when wheels may slip and after recover grip. To go further, should be great to know what driver profiles have people who met the failure. Sorry for long message and good luck for your upgrade ;-)
 

Miguel Freitas

Registered User
Parts are being fitted this week
Hello again,

do you have the parts already fitted into your car?

I received today the TTE470 I will be testing in my car after this thursday dyno with my orignal turbo with hybrid solution from CR Turbos in Portugal.
If everything goes well I will then fit the TTE470 and do another run in some weeks.

Assuming I will achieve great power results I really need the CV joints :D
 

DTYME83

Registered User
Hello again,

do you have the parts already fitted into your car?

I received today the TTE470 I will be testing in my car after this thursday dyno with my orignal turbo with hybrid solution from CR Turbos in Portugal.
If everything goes well I will then fit the TTE470 and do another run in some weeks.

Assuming I will achieve great power results I really need the CV joints :D

Still a work in progress but it's almost there

DTYME83
 

AGee

Registered User
I received today the TTE470 I will be testing in my car after this thursday dyno with my orignal turbo with hybrid solution from CR Turbos in Portugal.
If everything goes well I will then fit the TTE470 and do another run in some weeks.

Did you consider fitting the TTE525R?
 

DTYME83

Registered User
A complete set of shafts and cv joints should be produced in the next 2 - 3 weeks would like me to add you to the list

DTYME83
 
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