Driveshaft issue

[Dutch205er 0]

Hello,

I drive a 205 GTI with TCT engine for 3 years, now the outside CV joint on the left is broken.
Bought another driveshaft, then I noticed it didn't fit in the gearbox..
I don't know what box i have, i do know it has an stronger dif.

 

Therefore, the inside spline has been made longer.
Then i tried to put the outer CV on the old driveshaft, BUT:

Mine is 21mm thick, the new one is 18 mm..

What outer CV joint do i need?
 

[SRDT 255]

Aftermarket driveshafts can be a mess. You just buy a part that fits, what's inside and how long it will last that's another story.

 

Here is more about the two diff sizes and also drive shafts:

 

[Dutch205er 0]

Thanks!
What a mess with those driveshafts!
There are almost no aftermarket ones left,,

[Dutch205er 0]

Still not able to find the correct driveshaft..
I brought the broken one to a company who will fix the problem.

I had the head worked on after a leaking  head gasket.
Yesterday first start after reassembling, the engine is ticking like crazy..

 

Did the revision company did mix parts?
Now i have to measure and adjust the shims.

Might as well throw in a DKZ camshaft, there is one for sale.
But the caps? aren't numbered.
Will this be an issue?

So first the old one out, new one in, measure, adjust the shims.

Is this correct? 

 

Can't upload here, so put it on YT:

i

[DamirGTI 366]

Sounds like gearbox input shaft bearing to me , does the sound go away when you press the clutch pedal in/down ? 

 

Camshaft caps are numbered , but the lifters/buckets arent .. 

You'll need to remove timing belt as well if changing the camshaft .. there is some tricks around that but it is a bit fiddly .

 

Also would be good to resurface the buckets/lifters , if they're not deeply worn/dished you can do it by hand and some sanding paper .. and re-adjust the valve clearance on the end , that will make really nice quiet engine .

 

No so hard for DIY if you have time tools and paitence . Haynes manual is good as a guidence "how to" .

[petert 641]

I don’t chance 8V buckets anymore. They’re so cheap now it isn’t worth the time and risk to re-surface them.

[Dutch205er 0]

Damir makes me think, the short driveshaft isn't in atm..
Will spend the day reading and searching for how to move on,
Just learned how to change the timing belt etc.

Maybe adding VEMS or a similar upgrade ECU, bigger injectors.

[DamirGTI 366]

Seems like it'll be the gearbox .

I've had a few with the same sound, and it was the input shaft bearing , not a bad bearing , but a lack of bearing preload .

TCT engine seems to be good for tuning , but it's heavy on fuel consumption .

Mine is on LPG for that very reason .

I haven't tried driving it yet though ,  need to finish putting it back together !

How is yours on fuel ?

I guess a little bit less, as the 205 is light, but it still seems to be around 10–12 L/100 km .

Peter, yes new buckets are cheap , but as with a lot of stuff nowadays I guess the metallurgy isn't that great aka Chinesium grade... I've seen a few people doing hardness testing on new engine parts and the results aren't great .

[Dutch205er 0]

Found out today my gearbox is a box from a Xantia 1,9TD.
Code 20CL68. BE3.

Bought the DKZ camshaft, also bought a second hand driveshaft from the Xantia TD, 10 euro
Will arrive this week.

Then fiput the driveshaft in, start the engine again.
Fuel consumption never looked at with this engine, probably 12-14 liters 100 km,
always pushing.
Impossible to drive slow/normal.

Edited September 27 by Dutch205er

[welshpug 1,737]

Most  Td gearboxes have the larger diff gears like the xsara etc, so require the shorter left shaft stub.

[Dutch205er 0]

The TD axel wasn't available ;/ Money back.

The company who would fix the thread on the driveshaft didn't deliver, 2nd time "next week"

 

I used Gemini to find out i need the GSP 817028 CV joint. 

25 outside, 24 inside.

 

The GSP CV has a different profile underneath the outside spline, so this one might also be not usable..

 

And I guess i have to remove the innet CV to measure the length of the axle..
Or find a company who DOES deliver the refurbishment of the old one.

[wicked 107 3 Cars]

3 hours ago, welshpug said:

Most  Td gearboxes have the larger diff gears like the xsara etc, so require the shorter left shaft stub.

Or convince yourself that this is a good reason to buy a quaife diff and complete gti shaft...  

[welshpug 1,737]

or that yes.

[Dutch205er 0]

Ok, was thinking about a quaife..

Is the 20cl68 gearbox suited for the quaife 205 one?

[DamirGTI 366]

That CV joint looks like the one from 309 1.9 D/TD .

And maybe complete driveshaft is 309 1.9 D/TD too .. 

 

Pretty much all the other CV joints have hole drilled trough for "R" clip , the one from the 309 D/TD does not and it's the same teeth count as the GTi CV joint and some others too .. 

 

I had an 205 here with such 309 diesel driveshafts and yours look very similar to those if not the same .

Not sure if i have any pictures , i'd need to look ..

 

Which hubs do you have 205 1.9 GTi or 309 GTi along with 309 GTi wishbones ?

[DamirGTI 366]

Nope i was wrong ! , that one had different CV joint type which cannot be separated from the shaft .. and tin sleeve inner tripoid joint cup like on base models .

 

But the teeth count/thickness was same as GTi CV joint .

Edited September 29 by DamirGTI

[Dutch205er 0]

2 hours ago, DamirGTI said:

That CV joint looks like the one from 309 1.9 D/TD .

And maybe complete driveshaft is 309 1.9 D/TD too .. 

 

Pretty much all the other CV joints have hole drilled trough for "R" clip , the one from the 309 D/TD does not and it's the same teeth count as the GTi CV joint and some others too .. 

 

I had an 205 here with such 309 diesel driveshafts and yours look very similar to those if not the same .

Not sure if i have any pictures , i'd need to look ..

 

Which hubs do you have 205 1.9 GTi or 309 GTi along with 309 GTi wishbones ?

 

2 hours ago, DamirGTI said:

That CV joint looks like the one from 309 1.9 D/TD .

And maybe complete driveshaft is 309 1.9 D/TD too .. 

 

Pretty much all the other CV joints have hole drilled trough for "R" clip , the one from the 309 D/TD does not and it's the same teeth count as the GTi CV joint and some others too .. 

 

I had an 205 here with such 309 diesel driveshafts and yours look very similar to those if not the same .

Not sure if i have any pictures , i'd need to look ..

 

Which hubs do you have 205 1.9 GTi or 309 GTi along with 309 GTi wishbones ?

Normal standard huis, normal wishbones.

[DamirGTI 366]

10 hours ago, Dutch205er said:

I used Gemini to find out i need the GSP 817028 CV joint. 

25 outside, 24 inside.

 

It's 25 outside spline and 23 inside spline what most of the smaller PSA cars have .

Are you sure yours is 24 inside shaft spline ? 

 

If it's 23 and if using std. 1.9 GTi hubs and wishbones then you can use 1.9 GTi driveshafts , or just buy 1.9 GTi outer CV joint and knock it on the driveshaft which you have as the gearbox side seems modifide to suit the diff or something i'm not sure .

 

Either complete known good used 1.9 GTi driveshaft  , or CV joint only .

 

If buying new try to find GKN/Spidan/Loebro (all GKN brands/same part) as only those will last , OE driveshafts where made for PSA by GKN .

Aftermarket CV joints like that GSP, Metelli , SKF and the likes all the same Chinese crap will go poop on a turbo car especially .

 

Edited September 29 by DamirGTI

[Dutch205er 0]

The wrecked CV is really 24 splines, the axl 21mm thick,and has 24 splines at the spline which goed into the CV even thicker..

Edited September 29 by Dutch205er

[Dutch205er 0]

Time-out

OK, I could just buy an Quaife dif, was planned for the winter 27.
Now I want to sort this out

206 axel looks like mine, but the difference in splines for 1 car ?!

Tomorrow i will call Bart Ebben,, and ask for advice.

And keep on searching.

[DamirGTI 366]

24 is a bit weird .. they are usually 22 / 23 / 34 .. 

Likely aftermarket driveshafts or something from another car brand .

 

Try search via this : 

https://size.name/en/catalog/shrus

[Dutch205er 0]

Nice site, but i miss some variable, like thickness of the axl..
This moring i delivered the CV to a company, end afternoon ready!
Not perfect, but ok for a few trips, 
The search continues

 

[Dutch205er 0]

Double..
The axl is in the car now,
leaving tomorrow for Stuttgart, Oktoberfest till sunday.
Didn't start the car yet.

I will first measure the clearance of the valves,
then change the DKZ camshaft and measure again.



 

Edited September 30 by Dutch205er

[SRDT 255]

On 9/29/2026 at 6:27 PM, DamirGTI said:

That CV joint looks like the one from 309 1.9 D/TD .

And maybe complete driveshaft is 309 1.9 D/TD too .. 

On the 205 GTI 1.9 you only have one "grade" of drive shafts because that's the only 205 with big hubs. On the 309 all XU/XUD have those big hubs so you find 3 grades :

1. XU51C, XU52C, XU5M, XUD7, XUD9 up to 07/1991
2. XUD7T, XU5JA, XU5J1, XU9J1, XU9M, XU92C and all of the others since 07/1991
3. XU9JA, XU9JAZ, XU9J4

As a manufacturer if you shorten the shaft to 205 length 1 and 2 will fit perfectly on a 205 GTI 1.9... they won't be as good as the real deal but as long as they sell why should you care?

[Dutch205er 0]

Problem is solved for now. Will order a Quaife diff in januari