This video provides a necessary reality check, proving that the transition to electric mobility still requires the same mechanical precision and rigor as traditional engines. It masterfully illustrates how even the simplest maintenance oversight can lead to catastrophic failure in high-speed EV components.
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Benzin im Blut, Hochvolt in der Halle: Meine erste E-Antrieb-Reparatur
Added:As you may have seen in the last video, I bought a Renault Zoe that has a blown gearbox. The story is also explained in the last video. I'll link it again up here. Um, a woman bought this car new 8 years ago and drove it 100,000 km. Then the lower control arms or the wishbones were worn out and had to be replaced. Then she took the car to Renault, to her authorized repair shop. They replaced the control arms, and after a year they were broken again. Then she went to Renault and they told her, well, the materials used nowadays aren't what they used to be. She said, well, I drove the car 120,000 km before and now 15,000 km, so it can't be that bad. Yes, yes. Anyway, they kind of just brushed it off. Then she went to an independent garage, they did it, and then she asked Renault, who said the repair would cost €8000 because Renault does n't do gearbox replacements or has gearboxes as individual parts; they only do it as a complete unit with the entire drive system. Um, she then tried to sell the car. I then bought it with a... well, ownership battery for €45,000. I had the car towed here and took a look at it.
May I tell you what I imagine it to be like?
Several people expressed similar sentiments in the last comment. This is my personal understanding and opinion of what happened. The previous owner of the car went to an independent garage and said she wanted the lower control arms replaced, and the company agreed to do so because, on French cars, when you pull the drive shafts out of the gearbox, oil leaks out.
That's why you drain the oil beforehand. They drained the oil at the oil drain plug, then worked on the control arms, meaning they removed the axle shafts because the wheel had to be removed and things like that. We'll get to the work on the control arm later. Then they repaired it, so to speak, plugged everything back in, and the customer drove home in the car after paying. In the good belief that they had new ball joints, at least. I need to check the invoice again to see if it also included the entire control arm with the ball joints that was charged for, because it was n't replaced 100%. But that's a different story. The priority now is getting the customer home. She lives not far away, I think about 5 km from the workshop, drives it and it starts to rattle from the gearbox or the engine. The customer could n't say right now. She calls the garage, drives to the garage the next day, and brings this car in because it's making a rattling noise. The workshop says: "Oh, a clicking noise from the front always comes from the drive shaft." It's strange that it's suddenly appearing now. But they install a new axle shaft, drive shaft, on the driver's side, test drive the car and at that moment there's a bang and there's a hole in the gearbox and the oil is leaking out.
Then the workshop called the customer and the customer replied, yes, I brought my car here because of the ball joints and the control arm and now the engine or the gearbox is broken and the car no longer drives. The repair shop said, "Yes, it has nothing to do with us, that just happens sometimes." The thing is, I assume the garage forgot to refill the oil after the first repair.
That's exactly the effect that occurs when I drive without oil with this gearbox, which makes a loud clacking noise. Because there's no oil in it to cushion everything during these mechanical movements. Those are high speeds and forces at play. The workshop has now installed this new axle shaft. At that point, at the latest, since they had to drain the transmission oil to convert the axle shafts, they should have noticed that there was no oil in there at all and had to pour some in. But they did n't do that either. That means the axle shaft was replaced, there's no oil in it. That's what I personally think happened. And we test drove the car and then the thing ran dry and broke down, and some part that was too hot or broken off or something else punctured the gearbox housing. Another piece of evidence supporting my theory is the cover that is under the car. Let's take a closer look at this thing. We can see here, this is roughly where the gearbox is.
This means that if the gearbox breaks down, 0.65 liters, or more than half a liter, of oil will go into the gearbox. If that had leaked out, I have a little oil here. So, this is probably what was left in the gearbox after draining the oil, I guess. If half a liter of oil leaks out here, this pan will look really filthy. This cotton wool here, which is normally saturated with oil, is not the case here. Oil would leak out down here, which you would then see on the other side. Let me turn it around. Of course, someone could have cleaned here, there's nothing wrong with that, but you would still be able to see it somehow. But if half a liter of oil leaks out here, it will look different. If they had said, well, we've cleaned this thing up because everything was oily, what else would need to be done? It wouldn't look like this.
This dirt on here is ancient.
So there's no way that much oil could have leaked out here. It will be very difficult to prove something like that, that much is clear.
I have now ordered a new gearbox, well, a used one.
Exactly what will fit in there will be revealed next Friday. But now let's move on to this other point, which was also important to me. And those were the wishbones. And what really surprises me are these weld points down here on the ball joint. That is not my opinion, and it is the opinion of many, many workshops I have asked; they all said that you are not allowed to do that.
This was done on both sides.
I'm curious to see if the customer has an invoice for the entire lower control arm being replaced. You can see that the wishbone at the back is older.
That probably wasn't resolved. It 's also a bit more complicated.
Same here, the rubber parts don't look new either.
We can see over here that it's also not a new rubber that's in there, and neither is it here.
Apart from that, if I have a workshop and I see that a carrier looks like that, then I tell the customer and offer to treat it somehow, to protect it. But things like that count, and so does the service. And as they say, service is not a German word. There's already a queue. And I will clarify with the TÜV (German Technical Inspection Association) whether it is allowed to do this with the ball joints, because the ball joints have grease inside, they have plastic inside, they have seals inside, and whether I can simply do something with a welding machine. I assume they simply said, " The removal is so complicated, so we'll just roughen up the area a bit to make it easier to insert the ball joint and then weld it in place." Then we save ourselves all the work, because I have to remove the axle assembly down here, and afterwards I might have to have the track remeasured and all that stuff. Actually, they could have also removed the rust from the frame at the front. There are a lot of construction sites involved.
Now, his latest video caused a lot of excitement when I said I was fed up with the buses and all the oil and dirt. And many then said, oh, I'll never leave the canal again. You're just as brainwashed by March as everyone else and all that. And I want to say it again, if anyone ca n't brainwash me, it's this guy from März who really kicks the ass of anyone who might be of any use to him. But let's not get too political now. It's quite simple, I'm someone who is enthusiastic about technology, about technology in general. And I've had too much to do with rust lately.
Peter, you said it so beautifully, or wrote it so beautifully. I had an overdose of rust. Yes, that was simply far too much, and far too much underbody protection. That really spoiled my mood. When I watch videos of the Waldbus, like Flo's, I think, oh, cool, to make a car like that, and I get the urge to do it again.
She will come back again. It will come back too, when I take the buses here for the first time and do that. So, this is not a topic I will leave out. Only the conversion to an electric bus is omitted.
I won't do that. And, um, there will also be one or two classic cars.
However, the current focus is on moving more towards electric vehicles, without neglecting the other buses. But the issue will simply fade away, not because it's environmentally friendly – that's a pleasant side effect – but simply because it's a great technology. I have extremely high performance with extremely low fuel consumption. I have things that last a very, very long time. I have clean jobs I can do on these cars. There are simply many, many things that play a role. And the fact that it's good for the environment is great too, but that's not my main motivation. Yes, and perhaps that's how one should see it. If I'm offered a car today, like this bus, for example, with a 50 hp engine and a consumption of at least 12 liters of premium gasoline, and someone tells me I can drive this bus without having to drive uphill at 20 km/h, but with a real pulse. You also have few repairs to do on your engine, and there's no more mess underneath it. Um, and the whole thing will cost you a third in maintenance of what the car would normally cost you. Here it might even be only a quarter. Um, then I would say yes immediately. And that is precisely the reason. Electric motors are really great things, but of course they also have their problems. Well, batteries are really something special, and the entire technology behind them is really something special. I want to make that absolutely clear. A quick disclaimer: everything I do here is not a tutorial or something that any of you should copy. If you are working on an electric car, then make sure you get a certificate beforehand for the work you are allowed to do. There are different things. You should check out the links I've included below to see where I got all my certificates; I have all the certificates for working on electric cars. Today I want to remove this engine. I have never removed an electric motor before. I have never repaired an electric motor before. I have never repaired the gearbox of an electric motor. This is my first time today and um, I'm curious to see how it works, what the difference is to my VW bus engines that I take apart and put back together. I 'm really curious. It's supposed to involve a lot of tinkering.
So, I hope you enjoy watching and keep your fingers crossed that everything works out. I had actually planned to work on this car on Thursday, Friday, Saturday, and Sunday and try to finish it. I started yesterday evening, Wednesday, and already took some things apart, and I have to tell you, it's really fun.
The thing is, there's actually no oil or any other mess or exhaust systems or anything like that here. Um, not that it is n't my field of work or anything, but it's a completely different way of working when you're really working on something so clean. It has a clinical feel to it. Yes, and the car looks good, it has many rusty screws and many places that are a little rusty, but overall it's really easy to work with. I have several different things now.
Here is my gearbox. This is the gearbox. Yes, I bought it from a recycler in Sweden via an online platform. The parts are significantly cheaper in Sweden than in Germany. I checked in Germany, and in the cheapest case, a used gearbox like that costs between € 1200 and €1800. Around 80,000 km. It's not a real gearbox, which has a lot of wear and tear and things like that, but rather it's just a conversion gearbox where I convert the 18,000 revolutions from the electric motor into a reasonable, um, speed, so that the 18,000 are not directly at my drive wheel.
And as I said, I bought it in Sweden, and it cost €580 there including postage and a warranty. I have 14 days to return it free of charge if I don't like it. The postage costs were included, as well as customs and everything else, but I don't think customs fees are included.
He's asking the wrong person. That's perfect, because of course there are many more cars, many more married cars, in Sweden than there are in Germany. That's why things are still a bit tight here. But that's great! There are these big platforms, you can see them all, all the providers and things like that. Not bad at all. Then, of course, I got the bearings.
I'll link them again below. That was great. They sent them on Monday and they arrived at my place yesterday at noon. They came via Charles de Ga Airport and then continued by train with everything else. That worked out perfectly. So, today we'll continue taking the vehicle apart and see if we can get the engine out today. เฮ [music] [music] [music] [music] เฮ [music] เฮ Yes, friends, now I'm back where I did n't want to be.
Normally, I could remove the gearbox here, attach the new gearbox, and then put everything back together. Now, of course, I'm being such an idiot again, because I told myself I want to replace the bearings on the motor armature, since that's a minor problem with the Zoei. After a certain time they wear out and then they become noisy, and when they become noisy, they generate heat. Then they break the engine sensor and various other things as well. This happens to some cars at 100,000 km, to some at 150,000 km, to some only at 250,000 to 200,000 km, and to some not at all.
Um, now the question is, if I've already got everything as far as it is now, should I just go along with it? I'll be annoyed later if I find something else that 's even worse, and then I could just bolt it on, screw everything together, and drive off. But if we already have all this, let 's do it properly, right? What do you think?
Yes, then we'll do it right.
Now open this one too.
Now he's fully open.
Now the engine is decoupled, so to speak, and then we can lift it out. That means I'll get the crane now and then we'll see what happens next.
Yes, that's the problem when you have to do everything on your own, but of course it's also fun, which I find really sad, when you're in the community of us YouTubers, who all have it tough, and you can just ask each other questions and help each other out. And that 's almost always the case. I recently heard about Jürgen Linse from, uh, I'll link the channel below. This is the specialist for VW bus engine conversions, and he also has a shop, which I wasn't even aware of.
I wrote to him and asked him, um, I had a question about the engine, a simple one, and he did n't answer it. He said, "Look, if you buy the stuff from me, I'll answer your questions, but if you buy it somewhere else, I won't ask you any questions. Give them a call." At first I was a little angry, but then I understood, because of course, I told him, listen, I didn't know you had a shop by now, otherwise I would have ordered it from you of course. I've ordered things from him before, but it was only about five or six items that he had in his shop. Um, I apologized and he was kind enough to give me the information anyway. So, thank you again.
Um, and he only makes air-cooled engines. If you ever need to work on a VW bus engine from a T2, a Beetle or something like that, Jürgen is exactly the right person for you. So, for this thing, I absolutely needed these bearings because, as I told you, being the blade I am, I want to do all of this. And now I knew, of course, that I'd have the gearbox by the end of the week, and then I'd need those things, because if I wait two weeks for it, it'll be very difficult. Then I already contacted this shop, which I'll link below. They said yes, they could send it out, but um, I wasn't sure about that, so I just contacted some YouTubers who I know work or have worked with these warehouses. And among them was, for example, the mechanic from Evoi.
I watched many things he did to Zoe. He seems to be quite a loner. I wrote to him, saying, "Here you surely have some in stock, couldn't you send me two, then I'll already have them." Of course I paid them according to your price, and I received nothing. And I already asked something, but got no response. And I think that when people have a YouTube channel and then don't actually want to have anything to do with their people, don't want to have anything to do with colleagues, and don't want to have anything to do with anyone else, then it's really a shame. Um, and I can promise you that it won't lead to success in the long run either. Then I saw that there is Otto Bärend from the IV Clinic in Berlin. I think there's also an EV clinic in Croatia. And these are guys who are really, really innovative when it comes to these things. And I wrote to them, and it's a really big store. Evoi is a small, uh, man-made workshop, as it seems, and the EV Clinic, they really do everything. They repair Tesla batteries and use very special technologies, and [snorting] it's truly perfect. Take a look at the videos, I'll link them below, and also thank you Otto for replying to me right away. He then wrote back to me, yes, we don't use them anymore. We now have ceramic bearings, but these ceramic bearings cost over €400 somehow. It was n't worth it for me to spend the money on the Zoe right now. Um, because if I do that now, and they're quite good, they'll last at least 100,000 km, and then the engine has to come out again, but you might have to do something to the bodywork anyway. Um, and he would have sent them to me immediately. So thank you very much for getting back to me, and uh, I think it's just perfect how we interact with each other. It's not like there are 100,000 YouTube colleagues asking me, and uh, of course I'm also advertising for you at the moment I show, hey, if someone has a broken Tesla, a broken Zoe with a story like that, I'm only doing these things for myself.
He can contact the Y Clinic.
I believe that replacing the bearings costs around €25,000.
I heard that in a video once, but don't dwell on it. Um, the thing is, the guys are really passionate about what they're doing, and the other thing is very disappointing, but maybe he just did n't see my email in the spam folder or something. I'm assuming the best of him. Okay, now let's lift the engine out of here.
Yeah, [sighs] I'll open it now. I'm really curious to see what the gearbox looks like.
Yeah, [ __ ]. I can't remove it like that because if I remove it now, the checkmark will be there. Then I sort of loosened the gearbox.
But I think I'll put the whole thing under tension again, because, well, let's just try it out first.
I hope it doesn't backfire on me.
So, there's nothing to see on the gearbox here.
That's not bad at all.
The wave still looks good. We don't have any real dirt with us. That's good.
Gram is kind of fun. You can say what you want. Okay, I'm going to lift the motor now and disconnect the connections at the bottom so that I can remove this high-voltage electronics and then get to the motor, so that it's a little bit on its own. Do you understand? This is, so to speak, the air conditioning system.
Unlike a normal car, it's not powered by a V-belt or anything like that, but simply by electric current. So you can simply install an air conditioner in a classic car by putting one of those boxes somewhere.
That's not bad, is it? But even for those who eventually buy it, it should be something they can enjoy for a long time. And if you're going to do something like that, removing an engine is no small feat. Not complete without, so to speak.
That looks clean, doesn't it?
But it also looks like I did n't even need to take it off. But it's good to see. เฮ [music] [music] [music] So, let's see what the cat has left for us.
[groan] A few pieces flew around.
Oh, oh, oh. Well, that doesn't look good. There's something there. There you can hear the wood shavings.
Well, it has to be said, a bit of a mess has gotten in there. Let's see which side has broken ranks. So, the warehouse is in order here.
Differential.
Oh yeah, the differential is toast.
Wow. Does this also have a hole in it up here? There 's a hole here and here. Let me show you.
So, this one comes through and this one comes through.
That really, really messed things up here.
[music] In the morning [music] I wake up feeling no pain long stretching [music] I get to remember it [music] I see [singing] is empty on one side [music] back in only place [music] I can hide in the morning I'm wondering [music] how I'm g get through the sick [music] and we and only your love g [music] I close the cur [music] swe shaking all [music] imagine you're [singing] here.
Looking up at the [music] I'm a better man [singing] with your love and without [music] stuck in [singing] the I may never [singing] make it out [music] in the morning.
I'm wondering how I'm [music] to get through the night.
only your love. [music] Yeah. Only [singing] you love only [music] you love only you love [music][singing] my heart.
[music] [music] LDE.
Take me a [music][singing] when you visit won you stop [music] I'm a better man with your love [singing][music] Never make it out.
[music] [singing] I'm wondering how I'm going to get through the [music] I'mck and we only your make [music] only your love only your love only [music] your love only your I 've now added a little music to the whole thing because the microphones somehow didn't work for me. I cursed it, I mean, I complained a lot about it at times, about always wanting to do everything perfectly, about always having that intention. I said, well, come on, just take the gearbox out and replace it with the new gearbox.
Unfortunately, once I had it out, I thought, well, I'll replace the bearings on the motor shaft too, because there's a problem with the Zoe, or with many electric cars, that after a few hundred thousand kilometers (in the case of the Zoe, sometimes even under 100,000 km in some models), the axle bearings on the motor shaft—these are the ones here— eventually break down, and then the car starts to hum like a bee when accelerating, then it gets louder, and with this humming, the ball bearing is basically broken, and this generates heat due to the increased friction. And this heat then damages many things on the engine, like the speed sensor. Now I said to myself, come on, get some new bearings and just put them in and then you'll have a 100% perfect car, but this bearing replacement is much, much more work because these engines do n't come apart like you see everywhere on YouTube.
Unscrew the lid, lift it up, take it out, and you're done. As you can see, they're a little rusty around the edges, and the rust bonds with the cast aluminum, making it almost impossible to get them out.
So, I really had to struggle and you can see how I use the puller to push the motor shaft out, um, so that I can somehow get it apart. So, I sat here and said, what a mess, now you've already damaged the bearings so much that they 're broken too, and you can't just put the engine back in.
And I sat there with this feeling of weakness, where I thought, damn, now you've wrecked this car. You've gone too far again. Can't you just do some repair like a normal garage would?
[snorting] But I just can't, unfortunately or fortunately.
And as you will see, in the end, um, it works out with the camps too. I was able to squeeze them out. The new bearings went onto the new shaft very easily. When they were screwed together, they pressed themselves into this aluminum casting, and so on. Um, and that was of course another really uplifting feeling. So, this thing, this huge risk, is what would have frustrated me incredibly. If that hadn't worked, if I got into the car and it didn't start, I would be incredibly frustrated. Unbelievable.
[snorting] But it's probably this tension that makes me do things like this. And then we'll see if it works in the end or not. They broke off the screw, the ground screw on the carrier, and I really don't feel like drilling it out. But that's important.
I'll replace the carrier in the barn. Very easy.
[ __ ]. [ __ ]. You might think it's not really that problematic, but somehow it is.
Now I have to support the engine from below and unscrew the bracket again.
Lower it slightly. Is there a little space there? I don't really want to put a Hagen on it again.
I really didn't see that, that [ __ ]. But I really don't feel like drilling it out and cutting threads and all that. There really is n't that much space here. I still have the mounting bracket, which means it's attached to the top and bottom of those things.
Now, um, I'm going to raise the thing so that I can just get the transmission jack underneath to catch the Mode Mode. Stef, nothing is given to you for free.
He is no present.
Well, that'll get us there too.
It's convenient that Renault provides extra storage space here. Those guys think of everything.
These are really just minor things. If you start drilling around in that little hole now, you'll drive yourself crazy, I can tell you.
And the second screw, what do we have up there? A 17-inch, I think. There 's another screw attached to the back.
Rich, luckily I didn't only notice this when the whole front was installed, otherwise you'd have a real laugh. Here he is. Do you see that? That's great fun, it brings joy.
And there are still some screws inside this part.
Perfect.
That's perfect.
Oh, I was really lucky there.
I was really lucky there.
[music] [music] [music] You think doing wrong?
[music] Pressure underground.
[music] Wundre [music] [music] [music] thunders [singing] Can we do that afterwards? No, I can't get to that anymore either.
Now it almost looks like a motor vehicle. Now we're trying to hook the thing up for the tenth time. You get especially good at it gradually.
That looks good. I just need to crawl under the car again now.
Okay, now we need to screw these screws in.
Okay, that's what we'll do now. Now we'll put the lid back on here in the corner.
Now let's see what he does, shall we?
Okay, I'll put the main fuse in for now.
Okay, now we have the battery. Please please.
How cool. I'm breaking down, man.
Oh, that's awesome.
The car drives after four days, this car drives. Madonna Mio, it's not displaying any error message. That's so awesome. That 's so awesome.
That's so awesome. That's insane. What an awesome job. That was an awful lot of work, I have to say. It was hard work, but it was worth it.
Hey, how awesome is that? That's really great.
So, I'm thrilled. I am absolutely thrilled. Craziness.
It worked. It's true, I've done so many things here in the last few months and somehow I would have been incredibly frustrated if this had n't worked out. That was a risk. I've taken the plunge and bought an electric car. I've never repaired an electric car before, well, I've worked on my scooter, but not the motor, not the bearings, not the gearbox, and this is the first time, with 100,000 million cables and all that. It was like a jigsaw puzzle; you'd see somewhere, " Ah, something didn't fit there," and something would go there, and eventually you'd find a spot, and then there were ten other puzzle pieces left over, and so on.
And the fact that the car is working now, I'm really close to tears, I have to say. I am so excited and it makes me so happy. All I need to do now is refill the air conditioning, put the floor covering and wheel arch covers back on, and then this car will be finished.
Incredible, incredible.
[music] [music] [music] เ [music] [music] This is what the morning after looks like. So, I drove the Autoch yesterday and I 'm absolutely thrilled that it works. Um, that the four days of work were worth it, that I managed to get this complex thing working, and that I can start this car after these 100,000 cables, after these 100,000 1000 plug connections and everything that was involved, that this car runs without error messages, drives and drives really well, and stuff like that. I am extremely, extremely thrilled. Well, in retrospect, that was really fun. If there had been anything that clouded the whole thing, I would have been extremely frustrated. But that's the thing. I'll try it out and, um, say, do it, because I simply say, whatever, I'm just like that, I have this kind of courage to leave a gap, to say: "Hey, I manage."
And that's when I always get that uneasy feeling, like when I couldn't take the engine apart because it wouldn't come apart, I had exactly that feeling where I said, [ __ ], now you've bought a car that you can't actually repair and now you've broken it so badly that you ca n't fix it at all and you actually need help from third parties or have to take it away somehow and you won't be able to fix it yourself and so on. Now it's like this, and that has given me a lot of conviction that it worked. I am, um, really proud that it worked out, that I managed to take apart my first electric car with, let's say, a massive intervention, i.e., to kind of dismantle the engine. Um, the gearbox wasn't really the problem, but getting that sorted out in a workshop like that, I need to keep things a bit more organized next time, that's really important. It's even better to sort the parts, and to document even better where I unplug what, where each cable was connected, and things like that.
Perhaps set up two more cameras that film the exact object at all times. I'm amazed at how the M 539 Restorations manage to do that, when they take apart a V12 engine and then put it all back together, down to the smallest screw. How do you even manage that? It's a mystery to me how you can organize it so that you know how the parts fit together afterwards.
You always think, oh, I can remember where that went, but it 's just not that simple. So, I'm totally happy with the car now. I'm looking forward to this time. The only thing I have to do now is get rid of the winter tires and, uh, I've already ordered new summer tires. They'll figure it out, and then yes, it will certainly be a nice time with the car. And if you know anyone who has a defective electric car that they would like to get rid of, just contact me and I'll see if it's something for me, a project. But first, it's the buses' turn to get back on the road, and then we'll see what happens next. Yes.
This car is really cool. The only difference is that my MG and my postal van don't have a sound generator or speaker when I drive below 30 km/h. It's kind of a given, but that does n't apply to these cars. Range 250 km.
This thing has 92 hp. Um, it's a cool car. It'll be a bit cramped in here with four of us, but otherwise it's a really, really good thing. Okay, I hope you enjoyed the video. You had just as much fun as I did and at some point you also thought, oh dear, this will never work out like me, and then you were happy with me about the result.
Then I would say, stay healthy and well, and I look forward to your comments, likes, and subscriptions. Thanks, see you later. Ciao. Ciao.
One more legal note. This video is not a tutorial or an invitation for you to do it yourself, but I am simply showing you how I did it. If you're doing work like that, make sure you have a certificate. At the Mobility Academy, which I've linked again below, I obtained all the certificates needed to repair electric cars, to repair batteries, to do all that. I did n't need it for myself personally, but it was something for me to learn and see what it looks like, that you can build a 190 volt battery even with these small 9 volt batteries. Not a rechargeable battery, but a 190-volt battery that can actually catch fire and stuff like that. So, simply to recognize and avoid the dangers that might arise later.
Therefore, don't imitate, but watch.
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