Technical BIG PROBLEM! One side of engine has fallen out!

Rowey · Sep 26, 2017

So, I get into the car ready to drop the girlfriend off at work early this morning, I pull off and about 7 yards up the road theres a big CLUNK, I lost the clutch line, so me being optimistic just thought it was the cable sheared of a sort. Opened the bonnet &... nope....

The passenger side engine mount seems to have just gave way, half of the engine is hanging to one side, looks like the shaft has popped out of the gearbox & the clutch cable has gone and is 'peeing' hydraulic fluid everywhere.

Help, where do I start??

I'll get some pictures when the sun comes up.

TIA

multipete · Sep 26, 2017

Jack gear box up slightly,to take strain off drive shafts to stop further damage to gearbox and driveshafts. Check gearbox mount to see why it's failed, snapped bolts or mounting.

Rowey · Sep 26, 2017

multipete said:
Jack gear box up slightly,to take strain off drive shafts to stop further damage to gearbox and driveshafts. Check gearbox mount to see why it's failed, snapped bolts or mounting.

I'll go and do that now. Thanks for the quick response. Looks like the passenger side engine mount has just failed, i found a rubber donut on the floor, I'm assuming thats part of the mount.

Ziggy122 · Sep 26, 2017

Rowey said:
I'll go and do that now. Thanks for the quick response. Looks like the passenger side engine mount has just failed, i found a rubber donut on the floor, I'm assuming thats part of the mount.

Oh dear oh dear....

U really beed as stated already go get the engine resting in a more normal position before doing anything else

Cables can be easily damaged so this could turn nasty quickly...
Id advise getting the battery amd battery tray out and find out why it snapped/broke

Has it had work dome in past and its never been tightened properly?
Was it crossed threaded using a windy gun?

That gearbox mount along with the engine mount you rarely hear fail... never seen it on ff....
You do hear the lower dogbone mouny failing tho.....

Pictures needed

Ensure the gearbox didnt loose a driveshaft seating and leak its fluid out
Check wiring harness for condition
Check driveshaft aimt become bent as a result either

Ziggy

Rowey · Sep 26, 2017

Ziggy122 said:
Oh dear oh dear....

U really beed as stated already go get the engine resting in a more normal position before doing anything else

Cables can be easily damaged so this could turn nasty quickly...
Id advise getting the battery amd battery tray out and find out why it snapped/broke

Has it had work dome in past and its never been tightened properly?
Was it crossed threaded using a windy gun?

That gearbox mount along with the engine mount you rarely hear fail... never seen it on ff....
You do hear the lower dogbone mouny failing tho.....

Pictures needed

Ensure the gearbox didnt loose a driveshaft seating and leak its fluid out
Check wiring harness for condition
Check driveshaft aimt become bent as a result either

Ziggy

Thanks for the reply Ziggy. On the Enthusiasts page on Facebook there seem to be a couple of people that have had the same passenger side mounting go it would seem.

It was a horrible noise and it looks horrid

I'm just going to get my jack from my Grandma's and get it supported, I've got all afternoon now so I'm going to go and get some pictures, if you could help me try and piece it back together by procedure that would be absolutely fantastic, really would appreciate the help!

Brendan W · Sep 26, 2017

I'd get the battery disconnected as well.
There may not be much slack on the positive, red cable to the starter, but the last thing you need is that cable sawing itself on something.

Rowey · Sep 26, 2017

Just about to go and take the battery out now. Got some pictures prior to doing so. I managed to get a little bit of weight off of it by propping up the gearbox, couldn't find anywhere else to prop it up.

Thanks for the help guys, would love to be able to try and fix this.

jimboy · Sep 26, 2017

I'd invest in a trolley jack & a pair of decent stands, safety first & all that.

ItsJustGizmo · Sep 26, 2017

Don't suppose you still have that rubber donut kicking about? I missed lunch earlier so.. you know...

flisko · Sep 27, 2017

Rowey said:
Just about to go and take the battery out now. Got some pictures prior to doing so. I managed to get a little bit of weight off of it by propping up the gearbox, couldn't find anywhere else to prop it up.

Thanks for the help guys, would love to be able to try and fix this.

put piece of wood between jack and gearbox to raise it higher and put driveshaft back in, use tightening belt around gearbox and lift it up
now you can move the car

new driveshaft gaiter 10 squid, clutch cable 5, gearbox mount 5, and you are good to go

judderbar · Sep 27, 2017

flisko said:
put piece of wood between jack and gearbox to raise it higher and put driveshaft back in, use tightening belt around gearbox and lift it up
now you can move the car

new driveshaft gaiter 10 squid, clutch cable 5, gearbox mount 5, and you are good to go

And what are the chances of being able to put a drive shaft back in with the wheel on while moving the engine around and having almost no idea of what you are doing??

Reminds me of when i helped my brother fix his car years ago and the car came crashing down just seconds after I got my head from under the engine.

Steve145 · Sep 27, 2017

Ok, that's a bit of a problem...

First, you need to get the box into neutral, easy if the gear linkages still work, otherwise you'll have to do it from the engine bay, might need to disconnect the gear linkages to allow it to shift into neutral.

If you have to go under the car, make sure everything is well supported.

Once you've done that, you're going to have to lower the box back down in order to get that drive shaft to go back together. With the box in neutral (or clutch depressed, but you said clutch hydraulics are fubar), you'll be able to rotate the end of the drive shaft sticking out of the box until things line up. Lower the box down on a jack, then gently raise it until things start going together, keep rotating the stub back and forth as you gently raise the box until you feel the shaft slide into place, then raise it up the rest of the way.

Then support the box somehow, a wooden beam across the front wings and a ratchet strap would work, you're not going to be driving anywhere.

Before moving the vehicle, give the brakes a quick visual check, gearbox might have ruptured some brake lines when it fell off. Handbrake should be ok, so favour that.

With help, push or very slowly tow the car to somewhere you can work on it in safety, you said you'd only gone a few yards, so hopefully you won't have to move it far.

I'm wary of saying "call a recovery truck" as they'll just winch the car on, possibly causing more damage, if you do, make sure you explain the problem to them.

If you've got access to a tractor with a front-loader, a big forklift, flatbed truck with a hiab or anything else that could lift the car using slings, that would be a quicker and better way of moving it without damage, but that all depends on where you are.

Rowey · Sep 27, 2017

flisko said:
new driveshaft gaiter 10 squid, clutch cable 5, gearbox mount 5, and you are good to go

Not sure, clutch hose looks intact, just lookes just its popped out of the slave. Will see when everything is remounted, will do that job last. Ordering a new Gearbox mount from FIAT parts, as mentioned- have connections with the parts department. (Fortunately) Getting a new Gaiter, cv grease & fluid.

judderbar said:
And what are the chances of being able to put a drive shaft back in with the wheel on while moving the engine around.

Think its a wheel off job to pop the shaft back in? I

Steve145 said:
Ok, that's a bit of a problem...

First, you need to get the box into neutral, easy if the gear linkages still work, otherwise you'll have to do it from the engine bay, might need to disconnect the gear linkages to allow it to shift into neutral.

If you have to go under the car, make sure everything is well supported.

Once you've done that, you're going to have to lower the box back down in order to get that drive shaft to go back together. With the box in neutral (or clutch depressed, but you said clutch hydraulics are fubar), you'll be able to rotate the end of the drive shaft sticking out of the box until things line up. Lower the box down on a jack, then gently raise it until things start going together, keep rotating the stub back and forth as you gently raise the box until you feel the shaft slide into place, then raise it up the rest of the way.

Then support the box somehow, a wooden beam across the front wings and a ratchet strap would work, you're not going to be driving anywhere.

Before moving the vehicle, give the brakes a quick visual check, gearbox might have ruptured some brake lines when it fell off. Handbrake should be ok, so favour that.

With help, push or very slowly tow the car to somewhere you can work on it in safety, you said you'd only gone a few yards, so hopefully you won't have to move it far.

I'm wary of saying "call a recovery truck" as they'll just winch the car on, possibly causing more damage, if you do, make sure you explain the problem to them.

If you've got access to a tractor with a front-loader, a big forklift, flatbed truck with a hiab or anything else that could lift the car using slings, that would be a quicker and better way of moving it without damage, but that all depends on where you are.

Thanks for the lengthy, in depth response. Appreciate your time. I managed to get the car moved back to outside my house, Luckily I dropped the car out of gear as I heard the engine mount snap when it happened, almost instinctively (lol). Ive currently got the supplied scissor jack holding the box up slightly to take some of the weight off whilst I get the parts. I could probably do with getting hold of a couple axle stands.

Thankfully, my dad knows what he's doing. Say's it looks pretty plain sailing all being well. Lift the box back up and the shaft should lift adjacently and should be able to pop it back in? Then remount the gearbox. Then look at redoing the clutch hose. Not sure if it is bust or not, I posted a photo of it above, it doesn't look threaded so did it just pop out?

Thanks all for the input. Greatly appreciated.

Brendan W · Sep 27, 2017

Replaced our slave cylinder recently and the hose was held in with a spring clip.

s and b · Sep 27, 2017

these mountings dont just break
a full investigation is needed by dad

Ziggy122 · Sep 27, 2017

Ull have lost all the clutch fluid = fluid tank that also feeds the brakes will be empty!!!
Ensure the brakes are working before going on road!

The clutch slave may need replacing and also bleeding

The drive shaft may slot back into place as you lift it up
Cant tell if gaitor survived or it ripped with clip

The mount cant be seen to find out why it failed

Ziggy

Rowey · Sep 27, 2017

Brendan W said:
Replaced our slave cylinder recently and the hose was held in with a spring clip.

Thanks for the confirmation, I thought it was, at least it looked like it was looking at the slave itself.

Ziggy122 said:
Ull have lost all the clutch fluid = fluid tank that also feeds the brakes will be empty!!!
Ensure the brakes are working before going on road!

The clutch slave may need replacing and also bleeding

The drive shaft may slot back into place as you lift it up
Cant tell if gaitor survived or it ripped with clip

The mount cant be seen to find out why it failed

Ziggy

Yep, clutch hydraulic fluid is on the road. Will fill back up and bleed the system. I've got my parts mate at FIAT research to order me a NEW gearbox/passenger side mount, cv grease, fluid & a new gaiter. The gaiter that is on does look like its ripped out with some force.

I do have a photo of the failed engine bolt mount, it literally sheared from the actual mount... not the thread. Anyway, should have the parts for tomorrow so will let you know how it goes.

Thanks for the reply Ziggy, Rhys.

multipete · Sep 27, 2017

When you fit the drive shaft back in to gearbox,check you have three silver metal rings,like thick finger rings,these must rotate,check these are in place,(first thing you hold/touch when you hold end of drive shaft inside what's left of the rubber boot. Better picture from top,of gearbox mounting would also be nice.

multipete · Sep 27, 2017

Brakes won't need bleeding as fluid out let for clutch is higher than brake outlet so brakes should be fine,as long as no brake pipes have been caught.

Rowey · Sep 28, 2017

Cheers Pete. Picking the bits up in an hour so I'll start on it, will post pictures and let you know how I get on a bit later.

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