VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - Laxman

Hey guys,

My friends and i are working on a materials cw working on a fracture analysis of a broken crankshaft of an almost new VW Passat. We are trying to find out as much as we can about this part including the material used to make it and the manufaturing method used.

Have already tried contacting the VW dealer and phoned the company but theyre all not helping much ?

I was wondering if any of you would know something about this or where i could start looking for it.

Any Information regarding this topic would be very useful and highly appreciated

Thank you :)

VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - Peter D
Surely it is under warrantee so you should not touch it. Regards Peter
VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - unthrottled
Wow! How did that happen? Crankshafts are one normally over-engineered, and can even heavily modified engines usually manage with stock cranks. What does the fracture suggest? fatigue or sudden shear? This is an usual problem.
VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - craig-pd130

According to a press doc I got on the 2011 Mondeos, the petrol engines have a cast-iron crankshaft but the diesels use a drop-forged steel unit.

No idea if they are machined from solid or a built-up assembly, however.

Did the crank break on its own, or did the failure of another component lead to the break?

VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - 659FBE
Nearly all diesel engines have a forged crank - made by heating red hot a single billet of alloy steel and bashing it into shape with a very meaningful machine. The journals and other critical surfaces are then machined and ground where necessary.

Crank failure is very rare - although I have seen a diesel crank break on a backfire which was caused by a fuel system fault.

If the originally posted failure is to be taken at face value, the warranty should apply - unless dear old VAG have found a way of blaming the user for this failure (wrong kind of car polish + "diagnosis" charge perhaps).

There always remains the possibility of faulty manufacture - an inclusion in the material perhaps. Warranties are designed to provide reasonable cover for this eventuality.

659.
VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - tdc

A metallurgist will soon tell you whether there was an issue with case-hardening or metal impurity ,an engineer will tell you if the machining was faulty.

Before finding a better life I did 4.5yrs on agricultural equip.My first complete engine strip&rebuild at the firm was on a David Brown tractor.Farmer said it was knocking badly and after removing the sump it was found the crank was completely broken across a web.....still ran though!

VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - craig-pd130

Even in motorcycling circles, where engines are in a higher state of tune and tend to get used harder, crank failures are usually the result of a problem elsewhere (especially with 2-strokes ... oil pump failure, rings sticking & breaking, needle-roller small end bearings failing and dropping needles into the crankcase etc).

VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - tony@tooting

The clutch manfacturer LUK have had several cranks fail where the original duall mass flywheels where replaced by a "soild" conversion. I would have to ask therefore, has the clutch been replaced? If its fitted/still fitted with a DMF is it functioning correctly?

VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - galileo

Many years back the crank on my 1950 MG broke, a diagonal fatigue fracture through the front main bearing - I was able to drive it five miles home as the only torque needed across the break was that to drive camchain and fanbelt

From my metallurgy studies (long ago) I think the usual material for steel crankshafts was some kind of 1% Cr/Mo alloy steel (known in those days as En19) or a Nickel alloy steel.

My MG crank fracture started at an oil drilling in the journal, had developed over many thousands of miles. In a fairly new car, either some material or manufacturing fault must have been present for a break to occur.

The question of DMF failure or a solid replacement is also relevant, without some damping effect torsional vibrations occur and may possibly lead to failure (though not commonly on short, stiff cranks, more severe on in-line sixes)

VW Passat 2.0 TDI 2009 REG - Broken Crankshaft VW Passat, need info ? - SteveLee
British car manufacturers tended to use EN40B for steel crank applications.