Driveshaft popped out - Got it repaired - Broke again on drive home from Mechanic

1997 TOYOTA STARLET
40,000 MILES • V12 • FWD • MANUAL
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GARETHUUJ
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I have a 97 Starlet Sportif with 40,000 miles. My nearside pass/side drive shaft had popped out of the inner cv or tripod joint, it had tore the rubber boot and the shaft was hanging down with the three tripod bearing on the end of the shaft still intact. The cv or tripod housing was still connected in to the transmission.

I brought the car to a mechanic and got a new driveshaft fitted. On driving home from there the car was making the same noise it was before the driveshaft originally popped out. On pulling out of a junction I felt the familar bang and had to bring the car to the side of the road. It wouldn't drive..I got out to observe that the new drive shaft had popped out too :-(

Any ideas on a solution or which part needs replaced?

All help is appreciated and I thank you for your time. I have included a diagram to give a better idea of what it looks like now.

Image (Click to enlarge)
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Jan 12, 2011 at 12:26 AM
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WRENCHTECH
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That really can't happen unless your using the wrong axle or the engine mounts are completely disconnected and the engine is moving dramatically. The correct axle just wouldn't have enough room to come out as long as the knuckle is in place and the inner housing is still in the transmission. He has to be using the wrong axle.
Jan 12, 2011 at 12:47 AM
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FIXITMR
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you need to find out why the first axle popped. something aint right. the question is, is something else just worn/broke or did you somehow damage something in your driving. if you didn't lose any tripod bearings bearings you can get a new boot and re-assemble it.
Jan 12, 2011 at 1:05 AM
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MMPRINCE4000
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The inner tripod is held in by a C clip, either wrong axle or a really bad motor mount.
Jan 12, 2011 at 3:24 PM
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GARETHUUJ
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Thank you for your prompt replies. It is much appreciated.

What do you think about this problem possibly being the gearbox differential locking up on one side and the force of the wheel moving foward causing the shaft to be forced out? I'm just making this suggestion as the mechanic to fitted the drive shaft thought this could be the issue. I just want to be sure of what needs fixed as I don't want to spend money on a part that is uncessessary.

I'm thinking of fitting a second hand gearbox and possibly a cheap clutch because the clutch isn't great.

Is this the drive train problem? I'm certainly not a mechanic but I'm thinking from a physics perspective this could be the problem? Thanks again for any more assistance.
Jan 13, 2011 at 1:04 AM
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WRENCHTECH
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If what you're say is that the inner joint is just separating and the housing is remaining in the transmission, it's physically impossible if you have the right shaft and the transmission itself is not moving away. There isn't enough wheel travel to give the tripod room to come out of the housing so either the shaft is too short to start with or the trans is moving away at times.
Jan 13, 2011 at 1:16 AM
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GARETHUUJ
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Thanks, Wrenchtech. The shaft was the the correct one. Is there anything I could look for to see if transmission is moving away or what is causing it? I can jack the car up and have a look although I'm not sure what to look for? Thanks again.
Jan 13, 2011 at 3:05 PM
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MARK021964
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Out of interest was this a costly job or did you think it was reasonable at the time.
Sounds strange but I have the exact same problem at 40,000 miles with the same year car (1997). Although your one was 4 years ago it seems 40,000 is the going rate for this problem.
So can you give me a rough price of what you paid at the time & was this a simple task or a big job.
Finally did you have the work done at garage or private.
Any advice would be helpful as I'm passing the car on to my18 year old son.
Also must say the engine in the sportif is fantastic runner as sometimes I've not drove it for 3 months & it starts up first time in all weathers & a little pocket rocket.
Oct 18, 2015 at 2:08 AM