drive shafted - the driveline services australia saga
I don't recommend Driveline Services Australia Driveshaft(s).
I was having problems with a shaking in my Canter when travelling at around 80kph and could not resolve it with wheel balancing or tyre changes. I went back to Daimler Trucks in Newcastle who advised the driveshaft needed replacing, even though it only had done 42,000klms, and that it would not be covered under warranty as it was a not standard driveshaft. I took the truck to Thorley Mechanical at Salamander Bay and while he was doing a service and other work he sent the complete driveshaft in to Driveline Services Australia (DSA) in Beresfield to have it balanced and/or repaired.
Jake Thorley phoned me on 24th April and advised that DSA had contacted him and that my driveshaft was not repairable and that to replace it would be over $3000. I thought that was expensive and he said they were going to replace it with a heavy duty unit. I agreed as I was due to leave on my trip in May and really had no choice.
The new driveshafts arrived, but did not fit!!! It was too short. Jake was equally amazed as DSA were given the original driveshaft and he contacted DSA who agreed to replace it with the correct size as a priority, which took a couple of weeks. By the time it arrived I had little time left and had to load up and head off on my trip to Cape York.
I drove to Mapoon, above Weipa, with my slide on camper on the back and towing my boat, where I was to meet my Cape travelling companions. I had no need to use 4wd during the trip to Mapoon. I still had the shaking in the truck that I had hoped would be gone, so I thought it must not have been the driveshafts, so I had replaced them for nothing. Now not sure if I needed the driveshaft replaced at all. While moving the boat closer to the side of the campsite in MapoonI dropped two wheels off the gravel into the sand and it would not pull out in two wheel drive. I engaged the front hubs on the canter and put it in 4wd. As soon as it started to move there was an extremely loud bang, which frightened the crap out of me and everyone else in the vicinity. I got back out of the truck and one of the bystanders pointed underneath the truck where the front driveshaft was just hanging there. I had to remove the hanging piece of the shaft, disengage the hubs and take some air out of the rear tyres and the truck pulled out of the sand, relatively easily, in two wheel drive. This was the very first time 4wd had been engaged since the new shafts were installed.
I contacted Jake Thorley on 27/6/25 and he in turn contacted DSA and arranged a replacement. Unfortunately it did not arrive that week or the next week. I heard from the transport company that they had a truck arriving in Weipa late on Friday July 11th. I paid for someone to go from Mapoon to the transport company on Saturday and pick it up. When I got it, I fully removed the old drive shaft and fitted the new and greased everything. It seemed good till I started the truck and put it in 4wd. There was a grating noise when it was in 4wd which was not there previously. I contacted Jake Thorley and advised him. I later noticed that the noise was worse when the truck was loaded with the camper.
I consulted with some mechanics in Weipa and they advised that the noise was coming from the transfer case or the front diff. While they could not say how bad it may be they advised against continuing on a 4wd trip around Cape York. My travelling companions had left by this time so it would have been a catch up trip to join them, and then there was no guarantee of the front driveline totally failing and leaving me stranded in some remote area. Sadly I sat at Mapoon for a month then travelled slowly home, 2wd only and sticking to the main roads. Not happy.
I also spoke to someone at DSA (Brisbane?) who were after the broken driveshaft. I told them about the noise and they said that they had an idea of what it may be, but would not elaborate.
Subsequent to this I have had several plus requests for the return of the broken driveshaft. So much so that I became suspicious that they wanted it back as it was evidence of their faulty workmanship. I took it to a couple of other driveshaft businesses and they agreed.
After I arrived back home I contacted Newcastle Gearbox and Diff (NCD) to organise any repairs needed. I went to them as they specialised in gearboxes, differentials and transfer cases. I had to wait two weeks to get in to see them. They acknowledged that there was a noise somewhere but could not tell if it was the front differential or the transfer case. They said that on the balance of probabilities, whatever was causing this noise was due to the broken driveshaft as it would be too much of a coincidence due to the fact that the noise was not evident beforehand.
They asked me to bring it back in when they could have it for a full day so they had more time to examine it. I again had to wait nearly two weeks to get an appointment, They drained the oil from both the front diff and the transfer case. When I went back the manager advised that the oil from the diff was OK but the transfer case had metal in the oil and there was a leak. He said that it is a big job to pull out the transfer case and until they get it out, they won’t really know what the problem is. I was asked to book it in again, when they could have it for two weeks to pull it down and then get the parts and repair it. I did this.
As a courtesy I contacted DSA and advised of this. First comment was we want the broken shaft back. Then he said why didn’t I bring it in to DSA for repair. I said you are not gearbox, diff and transfer case specialists. I said it is not stated on the DSA website but he insisted that they were authorised gearbox and diff repairers. I knew I was morally obliged to let DSA repair the damage so I reluctantly agreed and cancelled Newcastle Gearbox and Diff. I was asked to bring it in on the 3rd December when DSA would have a transfer case specialist available. I said if you are authorised repairers you should have these people on hand? He said he had arranged to have them there on Wednesday afternoon and Thursday morning. I must also bring the broken shaft.
I explained to him that there is no way of telling what is wrong with the transfer case without taking it out. He said he was aware of that. Later he got back to me to ask that if DSA did take out the transfer case that I wanted them to go ahead and effect repairs. I said yes, but was on the same understanding as previously advised that if they were not going to repair it under warranty then I wanted it put back in so I could take it to Newcastle Gearbox and Diff.
On the way in from Nelson Bay again I called in to a couple of places to get further reports on the broken shaft and after they looked at the broken shaft, they assured me that all they needed was some photos and they could complete a report if required. I delivered the truck and broken shaft on Wednesday and was told that they would inspect it and pull out the transfer case and report back to me.
On Thursday morning I received a phone call advising I could come and pick up the truck he would not give me any details, just said we will explain it all when you arrive. Of course I knew that they had not taken the transfer case out and inspected it in that time frame so I believed I was being shafted. I suspected I was going to get surrounded by ‘experts” and howled down and convinced that any damage to the transfer case was not their fault. They did not disappoint.
My wife was with me, and just as well. They surrounded us and went straight on the attack. We were at the counter and the most senior DSA person (the Guy in Charge) was beside us on the left, the transfer case expert with the slightly foreign accent (the Expert) was in front and the local DSA (Anthony Scott?) was one the other side of us behind the counter. I asked why they were not going to repair the Transfer Case under warranty. The Guy in Charge said it was not caused by the broken driveshaft and said the Expert had completed and inspection, to which I replied that you can’t without taking the transfer case out. The Expert then advised that he had drained
the oil from the transfer case and it was clean with no evidence of any damage. Further he said there was a lot of “play” in the case, both ways and said it was just wear and tear. He also said there was a serious leak in the transfer case as the oil was low.
I advised him that of course the oil was clean, NCD had drained the oil from both the transfer case and the front differential in order to see where the noise was coming from and where the damage was. NCD advised the oil in the diff was OK but the transfer case has metal in it and that there was a bad leak. The Guy in Charge and the Expert both looked down and then at each other, but Scott then said “do you have evidence of this? Have you Got the oil?” I said “no NCD will verify this”. He said “they are not us” and laughed.
The Expert went on the say they did not notice any noise in the transfer case. I asked if they put it in 4wd. No Reply. Also I told them you can hear it in 2wd with the camper loaded hubs locked, but not as bad. Again they said they did not and again looked at each other. I suggested that the inspection was not completed as discussed in that they were going to pull the transfer case out, the same as NCD would have done. The Guy in charge then went on the state that if they pulled the transfer case out they would not be able to get parts and I would be without the truck for 5 months. I said NCD had already confirmed parts and there was a two week turnaround till when they had finished whatever repairs were necessary. I would have had the repaired truck back on the 12th December if I had kept my NCD appointment. Now they can’t fit me in till the 12th January. Common sense had told me not to give the truck to DSA and I told DSA that giving it to them as a show of good faith, not rewarded. I actually told several people that I was wasting my time and that I was sure that DSA would find that the damage was not caused by their broken driveshaft and that all they really wanted was to get hold of that broken driveshaft. Still it is somewhat comical that the DSA experts came to this conclusion without knowing what that damage was as they had not inspected the transfer case.
I said that NCD were specialists involving 4wd, gearbox, diff and transfer cases. DSA were ‘specialists’ in driveshafts only and that was now actually debatable.
I then asked what was wrong with the two driveshafts that they replaced, as I had asked previously and not been told. Scott said they had really bad wear and tear and were not worth repairing. I asked why they would have had such bad wear after just 42,000 kilometres. The Expert said those trucks with a lift kit in them put everything at the wrong angle. He said they should have the driveline made after the super singles and springs and lift is put in. I said that the truck had all that fitted before the chassis was extended and the driveline fitted. They said then whoever fitted the driveline did not know what they were doing. I couldn’t resist laughing when I told them that they installed the original driveline. Again looked at each other and the Guy in Charge appeared to become agitated.
Then I asked how it could be that when the original driveshaft was sent to them that they replaced it with one that was way to small. No answer and changed the subject. I asked as to why the new driveshaft had broken when DSA had told Jake Thorley that they were supplying a heavy duty replacement driveshaft. Scott denied that Jake was told this. Other driveshaft specialists have actually looked at the broken shaft and said it was a heavier shaft as it was larger diameter which had necessitated a sleeve being inserted but perhaps not properly.
I then asked what had caused the newer front drive shaft to break, to which I was told “we are still examining it”. I asked was it still too short? Was it not made properly or not spot welded correctly? Definitely hit a nerve there. More aggressive. The Guy in charge said that DSA had replaced the front shaft in good faith but were not covering the cost or repairs to the transfer case. I said I brought the broken shaft and truck in good faith but you did not do what you had promised.
He said to stop talking when he was still talking and show some respect. My wife said “huh, how about you show some respect and stop talking over everyone. He said to her “you can shut up or get out”. To which I replied as I faced him “don’t talk to my wife like that.” He took a step back. I guess he realised he had overstepped the mark.
I said the last case I had against a mechanic and his supplier and their two insurance companies was a big win. We originally asked for $12,000 being the cost to repair their mistake and 8 months later they settled for $25,000. My solicitor was happy, I was happy, someone wasn’t. That was 3 out of three. My wife asked if DSA were insured and Scott said “I don’t know”.
I said this is going nowhere. I promise you will pay for my repairs plus the cost of my trip to Mapoon and back as the broken driveshaft and damage caused meant that the purpose of the trip, to visit and explore Cape York with my companions, was not able to happen. Then there are my incidental expenses travelling to effect repairs etc, as well as my legal costs. I would also require a complete new driveline, properly made and professionally fitted. No one, especially a court, would expect me to travel around Australia relying on DSA driveshafts with the problems I have had.
Subsequent to this I have received phone calls from Alex Files from Driveline Services Head Office in Brisbane. Alex has apologised for the broken drive shaft and confirmed it was Driveline Services fault. He said he had spoken to Newcastle Gearbox and Diff and that if they confirmed that the cause of the oil leaks and the noise in the gearbox or diff was caused by the broken drive shaft, Driveline Services will cover the full cost of the repairs. He then sent me an 11 page report prepared by Newcastle Branch of Driveline Services. The inspection results included the following:
4.1 Several Oil Leaks evident on gearbox and transfer case.
Well it can be easily ascertained that there were no oil leaks evident when Jake Thorley had the truck in for service and to fit the new driveshaft immediately prior to my trip North. There were no oil leaks evident when I fitted the replacement drive shaft with the help of a friend in Mapoon, so any oil leaks happened after that time.
4.2 Excessive End Float from front and rear Transfer Case Output Shafts
Again this was not observed by Jake Thorley. Not sure what would cause this but there was no noise coming from underneath prior to the broken drive shaft.
4.3 Oil Residue Evident on Chassis Rails and Surrounding Componentry. This indicates leaks have been occurring prior to any failure.
What a lot of bullshit. There were no leaks before I left, there were no leaks evident when we fitted the new drive shaft in Mapoon. To get from Mapoon to Nelson Bay is around 4000 kilometres so that was when the oil leaks happened, after the driveshaft broke and caused the damage.
4.4 Oil drained from Transfer Case and Measured. Transfer Case filled to correct level and redrained and measured. Oil levels found to be different by 500ml when checked. Transfer Case filled to correct level and viscosity.
So they have confirmed that there is an oil leak. Well done.
4.5 Residue found on Magnetic Plug. No metallic particles found.
This would be because Newcastle Gearbox and Diff had drained the transfer case three weeks prior to the Driveline Services Inspection. They found metal particles. Anthony Scott said “but that is them, not us. Do you have photos to prove this”. I said you can talk to Newcastle Gearbox and Diff but he just laughed.
4.6 Vehicle has had excessive suspension lift and large tyres fitted to vehicle. This will exert extra stress on Drivetrain components due to extra Drive Shaft working angles.
I asked if the drivetrain fitted could have caused a problem. I advised them that the super single wheel and suspension upgrade were complete before the drivetrain was fitted. They said that the people who fitted the driveline did not know what they were doing. Driveline Services Newcastle fitted the original driveline. I am now of the belief that having admitted that the driveline as fitted by driveline services was wrong and still is that I should get it replaced by someone who does know what they were doing.
4.7 New Replacement front drive shaft has impact damage which is consistent with hammer strikes. Driveshaft working angle is also severe.
Saw no impact damage when I installed it in Mapoon. I doubt that anyone got underneath the truck on my way home with a hammer. I am equally confident that Newcastle Gearbox and Diff did not attack it with a hammer. Best guess is that it happened at the time of their inspection.
4.8 Major oil leak from rear output seal. Contributing factor to low oil levels which may cause damage to internal componentry.
Another outstanding observation. But what could have caused the leak???
There are a huge number of these trucks fitted with the same or similar suspension but I have not found one that has had problems. I am guessing they all had their drivelines made elsewhere??
When searching the internet for answers I was sent this piece of credible information:
Can a Broken Drive Shaft Damage a Transmission?
Yes. Driving with a broken drive shaft can cause serious damage to your transmission.
In Front Wheel Drive (FWD), Four Wheel Drive (4WD) and All Wheel Drive (AWD) vehicles, the drive shafts are connected to the front differential. The front differential is typically built into the same housing as the transmission.
Driving with a broken drive shaft can damage the differential, transmission and the housing. This may cause problems like:
Cracked differential and transmission housings
Broken or damaged gear sets
Damaged bearings, bearing housings and carrier bearings
Broken or damaged drive shaft splines
Damage to steering, brakes and suspension components
Damage to wheels, hubs and tyres
Major transmission oil leaks
The advice also stated that the vehicle should be towed to a drive shaft specialist for repairs.
That would have cost a pretty penny!!!
This is a direct quote from the website of Driveline Services Australia.
SUMMARY.
Daimler Trucks Newcastle advised that the driveline may need replacing as this was what was probably causing the shaking in the steering.
My mechanic, Jake Thorley, removed the driveline and sent it to Driveline Services Newcastle who advised that the whole system needed replacing, but did not say why. I accepted this based on what Daimler Trucks had said.
Driveline Services Newcastle sent the new driveline to Jake Thorley - it did not fit, it was too short, yet they had the original so how could they get that wrong.
They sent out another and it was fitted. I left on my trip North. The shaking in the steering was still there. So either the new drive shaft was faulty or the old one did not really need replacing.
Arriving in Mapoon my new front driveshaft failed with a loud bang, as soon as I put the truck in 4wd. Driveline Services have since admitted that this was their fault as it was only spot welded..
I contacted Driveline Services and they said they would send a replacement front drive shaft. I asked if I could just purchase one from AAV4x4 Brisbane, who had them in stock, as I only had a small amount of time before my planned trip was due to start. They said no and they would send me a new unit from Driveline Services Brisbane. At the time I advised Driveline Services that AAV4x4 advised that the front drive shaft for a Canter with parabolic springs fitted needed to be 565mm closed and 760mm open.
The new driveshaft finally arrived but too late for my trip around Cape York. Worse still was the fact that when it was installed there was a serious noise coming from the vicinity of the drive shaft.
I spoke to a few mechanics and had a mechanic from Weipa have a look at it and all agreed it would be very risky to continue to travel in the remote areas of Cape York with it as it was. All agreed that there was likely damage to either the transfer case or the front differential. So I had to return home.
Back home I booked the truck into Newcastle Gearbox and Diff. They could not say for sure where the noise was coming from but assumed it was the transfer case as there was an oil leak there and when they drained the oil there were metal fragments Inside. They had me book it in again for when they had time to pull the transfer case out, which is apparently a big job.
I advised Driveline Services what was happening and they said they wanted to do the job. I asked if they were qualified with regard to gearboxes and differentials and also if they were going to pull the transfer case out and find the problem. They said they were but were fixated on getting the failed driveshaft back.
I cancelled my appointment with Newcastle Gearbox and Diff and agreed to take the truck to Driveline Services Newcastle. The day after I delivered it, they phoned and said to come and pick it up. They had not done any of the promised repairs and in fact were rude and later supplied a detailed report saying nothing.
I again booked it into Newcastle Gearbox and Diff. They pulled the transfer case out and replaced the seals which were leaking. There was no leak before I left, as Jake Thorley will confirm. There was no oil leak prior to the drive shaft breaking, as confirmed by myself and others who helped install the new drive shaft in Mapoon. Newcastle Gearbox and Diff advise that they don’t know what caused the transfer case oil seal to leak but stated it could have been some rubbish inside. That is unlikely given the fact that the transfer case has breathers a substantial distance above the normal breather and the oil leak only appeared after the drive shaft broke.
I consulted various mechanics and specialists. When searching for answers I was sent this piece of credible information from a drive shaft specialist.
Can a Broken Drive Shaft Damage a Transmission?
Yes. Driving with a broken drive shaft can cause serious damage to your transmission.
In Front Wheel Drive (FWD), Four Wheel Drive (4WD) and All Wheel Drive (AWD) vehicles, the drive shafts are connected to the front differential. The front differential is typically built into the same housing as the transmission.
Driving with a broken drive shaft can damage the differential, transmission and the housing. This may cause problems like:
Cracked differential and transmission housings
Broken or damaged gear sets
Damaged bearings, bearing housings and carrier bearings
Broken or damaged drive shaft splines
Damage to steering, brakes and suspension components
Damage to wheels, hubs and tyres
Major transmission oil leaks
The advice also stated that the vehicle should be towed to a drive shaft specialist for repairs.
Suffice to say it seems obvious that the oil leak was caused by the broken drive shaft. Photos taken under the truck at the time of replacing the broken drive shaft show no signs of an oil leak.
Newcastle Gearbox and Diff then then pulled the front diff out and again found nothing. So they jacked the truck up and put it in four wheel drive and advised the noise appeared to be coming from the front drive shaft. So it would appear that the third drive shaft supplied by Driveline Services was the cause of the noise and vibration.
To prove that this was the case, I purchased a new front drive shaft from AAV4x4 and you would not believe it. No noise and no vibration!!!! This driveshaft was the correct size, as advised to DSA before they sent me this new drive shaft. Thinking back, they were very keen to come down from Brisbane to my house before Christmas and swap the new drive shaft over. They must have had their suspicions about the drive shaft being the cause of the noise and subsequently causing the leak. I, like everyone else, was convinced at the time that there was a problem where the oil leak was as that seamed the most likely. No one else thought to check the (3rd) new drive shaft.
Anyway, now that the problems have all been solved, all that remains is for the people responsible to pay for the damages due to their mistakes. I have sent an invoice, a once only offer, for them to pay the cost of my fuel to Mapoon and back as I did not get to go on my tour around the cape with my companions. However my travelling companions do not want to do that trip again so I feel it is an opportunity lost. Had I tried to do the trip this year, the fuel would have cost twice as much. There are other expenses I had which I did not include but I believe I am entitled to be reimbursed.
A quality made Driveline Services Australia Drive Shaft - Spot Welded
Images of the quality work of Driveline Services Australia
