Dist Gear life and failure conditions Q.

wolff at turboquattro.com wolff at turboquattro.com
Mon Aug 5 13:50:13 EDT 2002

Thanks for the correction. I'm glad that we have such great technical
knowledge on the list or our cars would certainly be much more difficult and
expensive to maintain. I just wish the nice metal gear had been available
when my gear broke. I may have to go the jewelry route. Let's see, key fob?
No that'll put too much hanging weight on the ignition switch. Maybe a
choker necklace. Yeah, that's the ticket!
"Nobody can forget the sound." - Michele Mouton

----- Original Message -----
From: "Bernie Benz" <b.m.benz at prodigy.net>
To: <wolff at turboquattro.com>
Cc: "200q20V mailing list" <200q20v at audifans.com>; "audi-20v"
<audi20v at rennlist.org>
Sent: Monday, August 05, 2002 11:57 AM
Subject: Re: Dist Gear life and failure conditions Q.

> Wolff,
> The plastic gear was injection molded onto the knurled surface of the hub.
> The hub insert being a piece that was inserted into the mold before
> and injection.  The mold was a very poor design, improperly gated,
> accounting for the gross tooth to tooth  and clearance errors of the
> finished gear.  Further, the plastic material used most probabily was
> selected primarily on cost, rather than as the best possible material for
> the application, including longevity in the application enviroment.
> So, Bosch and Audi eventually realized the short sighted error and,
> of correcting the poor plastic design, ran back to the old standby, a
> machined steel gear.  The latter being the better choice for a relatively
> low volume part.
> Bernie
> > From: wolff at turboquattro.com
> > Date: Mon, 05 Aug 2002 10:38:27 -0700
> > To: Bernie Benz <b.m.benz at prodigy.net>, 200q20v <200q20v at audifans.com>
> > Subject: Re: Dist Gear life and failure conditions Q.
> >
> > Looking at the failed gear from my 200 it looks more like the plastic
> > and split on the axle due to internal stress from being pressed on. The
> > rattle certainly won't help, but it wasn't a factor in this case since
> > was no rattle in my car prior to the failure.
> > HTH,
> > Wolff
> > "Nobody can forget the sound." - Michele Mouton

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