Dist Gear life and failure conditions Q.

[wolff at turboquattro.com]

Bernie,
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!
Wolff
"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
closure
> 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,
instead
> 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
aged
> > 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
there
> > was no rattle in my car prior to the failure.
> > HTH,
> > Wolff
> > "Nobody can forget the sound." - Michele Mouton