Front drive shaft broken

[PDX_Keith]

According to some digging I did today, there is no new part number

It's probably in the new fiche where it lists "Repair and wiring diagrams for customer's"

 

[AWo]

Has the part number for the front driveshaft changed for 2025 to confirm a possible upgrade? I doubt IA would offer any free upgrades for pre-2025 models (at least I’d be shocked if they did) but maybe for those who recently suffered failures might get one?

It would not be the first time that IA ignores that a new or changed part should get a new part number. They already created some mess by not doing so.

Hopefully they have learned.

AWo

 

[Zimm]

Seems like creating a new part number could be documented evidence the last part was insufficient to the task of the lift they green lighted, and would increase liability for covering the 3000 lifts people put on.

 

[C-Mack]

I would have to assume a new part number would be mandatory should any revision to an exist production component occur simply for tracking information related to source vendor used, design specification changes, costing of new part, production batch tracking, VINs of vehicles the revised component has been installed into, etc…

Not using a new part number would create considerable liability issues should the new part be subject to a recall after causing accidents or injures and Ineos could not identify the exact parts impacted. Lawyers would be all over that sort of ambiguity if push came to shove during an injury lawsuit.

At a minimum they could use the existing part number but it would have to be documented in their production and logistic systems with a revision number. Likewise, the vendor (assuming the same one is used) for producing the part would have to insist on a new reference part number so they can keep the new version straight in their own ERP/Logistic systems for all the same liability reasons.

 

[AWo]

I would have to assume a new part number would be mandatory should any revision to an exist production component

Check the two versions of the headlights. At least in the begining they had the same number. That led to both version in one car, as it was posted here already....of course, at some point only the new version was shipped and mounted....

AWo

 

[HereinDaRockies]

Well the oem boot flakes off these hard plastic coating. Just brushing it with my finger tip results in that external layer cracking and falling onto the ground.

What is the coating on the driveshaft boot?

 

[TCMColorado]

The headlights were changed from V1 to V2? When did this occur?

 

[ADVAW8S]

You could have the same parts but the design is different. I listen to the podcast and I enjoyed it. Interesting conversation around the response by auto writers.

 

[AWo]

The headlights were changed from V1 to V2? When did this occur?

Thread 'Headlight Recall'

Aug 6, 2023

I was contacted by my agent yesterday in order to arrange a few minor fixes. While on the phone discussing everything IG and giving my largely positive feedback, the agent mentioned that there is currently a “check” being done on all cars that go back in on the headlights and that certain cars are being held until further instruction from Ineos. I was surprised by this and actually wonder if it might be that the headlights are too bright? I have noticed nothing wrong with my lights, my only observation is that they are mega bright and very good for country lane night driving. I hope they...

• JOB
• Replies: 67
• Forum: Electrical, ECU, HVAC, Lights & Infotainment

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AWo

 

[TCMColorado]

Thread 'Headlight Recall'

Aug 6, 2023

I was contacted by my agent yesterday in order to arrange a few minor fixes. While on the phone discussing everything IG and giving my largely positive feedback, the agent mentioned that there is currently a “check” being done on all cars that go back in on the headlights and that certain cars are being held until further instruction from Ineos. I was surprised by this and actually wonder if it might be that the headlights are too bright? I have noticed nothing wrong with my lights, my only observation is that they are mega bright and very good for country lane night driving. I hope they...

• JOB
• Replies: 67
• Forum: Electrical, ECU, HVAC, Lights & Infotainment

• 
• 
• 

AWo

Thanks. It seems this was fully sorted before Ineos made the first deliveries to the US.

 

[bamanuke]

As a side note, I'm not yet convinced that there isn't a problem with the compound used on the Ineos boot. Or possibly there is a heat issue. Or maybe a bit of both. My Terra Flex version of the joint is holding up well with no signs of failure yet.

mine also, just over 9000 miles on the Terra Flex, 99% "on road". inspect it every 2-3 weeks.

 

[GN4HIR]

My lifted IG is in the shop for various minor warranty items and a $900 oil change. I have a stock loaner. Would they notice if it didn't have a front drive shaft when I returned it? We have a LOT of catalytic converter thefts in Houston, I could probably blame them. I plan to quiz them on what they have seen / heard about this issue from corporate.

 

[Dokatd]

My lifted IG is in the shop for various minor warranty items and a $900 oil change. I have a stock loaner. Would they notice if it didn't have a front drive shaft when I returned it? We have a LOT of catalytic converter thefts in Houston, I could probably blame them. I plan to quiz them on what they have seen / heard about this issue from corporate.

It's not necessary to keep a spare drive shaft. At least not in regards to this problem. Sure you could damage the shaft on a rock, but that might be a bit over prepared in my opinion.

Rather, buy a couple of the Terra flex joints as spares. They are small and fairly light in comparison to a whole shaft. Now the problem is the stock joints on the IG have a crimped end cap and different bolt heads. So you will need the tool for the IG bolts. Also and more importantly you will need a battery powered grinder or worst case maybe a hack saw so that you can open the end cap of the stock joint to remove the retaining clip.

The new terra flex joints are fully serviceable, so once you change to the terra joint you will no longer need the grinder/hack saw. This could also apply to the tool for the bolts assuming you switch over to the terra bolts.

I will say it's a messy job so be sure to have a box of shop towels on hand. Great part is if your front or rear shaft fails all you really need to do is remove what's left of it and engage the center diff lock. Now you can drive to safety and repair your shaft at the hotel or home. You can drive indefinitely with one drive shaft.

 

[Mountain4x4]

No big issues, with quite a few miles on the Terra Flex here as well. However, still the slight drive shaft vibration I dont like.

 

[Tom109]

I listened to the Expedition Portal podcast today about the IG and Scott said that the 2025's that are built after the production pause have a new front drive shaft with a CV that has a higher articulation angle. Can anyone confirm that? Evidently they're offering fixes.

Very interested where this goes….

 

[Owain]

Hi all, so my front drive shaft came off today done nearly 14000 km.

Wasn't doing anything outrageous, just happened to be taking off (slowly while towing) when there was a loud bang and then I couldn't drive forward or reverse without locking the centre diff. The front drive shaft has come away at the rear end of the shaft.

Will let you know what happens with the repairs.

Edit 1. For those who are mechanically-minded (not me) the circlip is still intact, there is some damage to the shroud where the drive shaft meets the transfer case, from what I can see. I will know more in a few days once it gets looked at.

Edit 2. Initial diagnosis looks like the transfer case has seized which caused the drive shaft to brake, this all still needs to be confirmed though! So far the process has been great, the dealer has been in contact with Ineos and now we will see how it goes.

It seams that there has been a recall for transfer cases on some vehicles, I believe that mine was outside this range (built too early) but this has not been confirmed, and I haven't received any recall notice.

Edit 3. After a full inspection the transfer case is fine (not sized), it looks like the circlip failed which caused the jack shaft to come out. A new shaft is being flown to TAS (the only one in the country) I should be back on the road tomorrow or the next day.
I've had very good dealings with Buckley's motors in Launceston, and appreciate them fitting me in. Well done guys!

Edit 4. So the drive shaft has arrived but there is damage to a coolant line that needs to be replaced, this has pushed out the vehicle to be ready next week.

Edit 5. For reference it's been 2 weeks and 2 days since the incident and I just got my Grenadier back. The coolant line took some time as there wasn't a replacement so it needed to be made (as is my understanding) and they needed to fit me in.
While it was a bit longer than expected I'm glad I have it back and grateful it could be seen at short notice. Thanks

Edit 6. I've done about 35k on the replacement drive shaft with no problems so far.

Same with me today. Driving at about 40mph when suddenly a loud bang and jolt, then complete loss of drive. Felt like I hit a large pothole (I didn’t). It’s on the back of a lorry now, off to the dealership

 

[Walter]

Same with me today. Driving at about 40mph when suddenly a loud bang and jolt, then complete loss of drive. Felt like I hit a large pothole (I didn’t). It’s on the back of a lorry now, off to the dealership

Sorry to hear that...Is your Grenadier lifted?

 

[Owain]

Sorry to hear that...Is your Grenadier lifted?

No standard Fieldmaster. 2023 model with 20k miles

 

[Zimm]

Which one is typically failing, the case or the diff?

 

[Dokatd]

Which one is typically failing, the case or the diff?

The T-case side exclusively from what I can tell. Even in the case of the failed C clip situations.

The T-case side has a slightly higher angle than the diff and less airflow.