Polo GT diff problem...i think...

[pologt84]

I think the diff is shagged on my gt...firstly a 'clunking' noise was heard on slow initial pulling away and also on deceleration.  I could feel it through the wheel slightly, knowing it was coming from the transmission assembley somewhere.  I then went on one last long journey in it (before i was going to take it off the road any way) and the feeling in the drive of the car changed and deteriorated over a short period of time.  I had vibration coming through the steering wheel at higher speeds and on deceleration, the clunking noise was a lot louder.  Once home, raised the front, checked bearings, not the problem.  I rotated the nearside drive shaft at the drive flange end, coming from the diff, with the gearbox in neutral, and there was a considerable amount if free play before the diff felt as though it 'engaged' in any way.  The other side had no free play and felt smoother during rotation.  I removed the strut and drive shaft to get to the drive shaft flange, checking to see if anything was loose as i dismantled it, found nothing.  I rotated the drive flange and the free play was still apparent.  I removed the driveflange and emptied the oil into a container.  It had no major swarf or any metal bits in it, but it did look quite 'shiny' on the surface.  I basically 'fingered' (for want of a better word, ha) the splined recess in which the drive flange fits and directly felt play in the diff on clock wise and anti clockwise rotation.  The outer bearing had no play what so ever, definitely inside the gear box...I want to take the box apart, but before i do consider that, just wondering whether any one knows what may have happened?  I have been running it lowered 60mm on fk springs with venom dampers (bit gash actually) and 13'' ats classics...could running up and down the m4 at about 90mph (which is more like 80mph as the speedo is out) with the engine ranting its balls off at 5and 1/2 to 6grand rpm have just simply rapidly 'aged' the car and put immense strain on the gearbox and diff etc running at such speeds for the majority of the time?...

One more thing...it sounds like a stupid question, but does any one know where to top up the gear oil on the polo mk2f/mk3 (how ever you refer to it) gear box?  I put oil in the hole on the top of box, the one that has a plastic bung in it, and it just drained out through the box, onto the floor...wicked.  I was just hoping that its not a bung on the side of the box and i have to buy a pump to force the oil in...Would greatly appreciate some advice on that one because i don't have access to autodata like i used to (but that was never always a help any way, ha).  Any help will be appreciated, thanks!!

[hayesey]

could just be a CV joint?  The splined part inside the diff will rotate on it's own since it's an open diff.

The gearbox filler plug is a 17mm hex key to the right of the drive shaft, just above the drain plug.  I'm afraid you have just poured oil all over your clutch through that plastic bung, it is for setting ignition timing accurately.  You'll probably find the clutch will slip rather a lot next time you drive the car, if you just put your foot down and let it slip then the oil might burn off (usually best off doing this on a motorway) and be right as rain afterwards, or you might need a new clutch.

[pologt84]

  Ha, thats what i thought i might have done with the oil...still drives ok though as i had to move the car today...not so bad, s'pose ya learn.

Yep, i know which bung you mean, was afraid it might be that one...i'm gonna get messy, ha.

[pologt84]

With regards to the diff...i understand that it will rotate on its own, but the offside of it actually has free play and excessive movement with in it.  I can't explain very well, will have to post some pics but i've put it all back together now, ha.
Thanks for the advice so far...