Sharan hesitates and makes a zerrt noise

[oldlegs]

Hi, our 2008 2.0 TDI SE 140ps manual Sharan sometimes hesitates and makes a zerrt noise just for a split second when accelerating only in 1st or 2nd gear at about 2,400 rpm. It has been suggested that the ESP was activating but this car has no warning lights or switches relating to ESP, indeed  the car will spin the front wheels in snowy conditions with no interruption or warning lights. this car has had new front discs and pads, a new left/front ABS/pad wear cable. I have driven the car with all 4 ABS sensors pulled out from their holders and it still did the hesitation/noise. I have also changed the front drive shafts and checked the splines on the inner right shaft.
    This car is doing a great job for us but the wife is loosing confidence in it, the car has only done 50,000miles so any help would be good so we can keep the car. Thanks Steve.

[Mirez]

At those revs it's right where the EGR will be opening fully. Given how prone these are to gumming up, coupled with what is very low mileage (normally indicating short journeys) I would pull it and take a look.

[oldlegs]

Thanks for the very quick reply, would a gummed up EGR only affect the car in 1st and 2nd gear and would it make the distinctive zerrt noise. The wife is at work in the car just now. Also may I mention another strange thing about this car I have replaced the left drive shaft 3 times with different makes and they all appear to be too short. I have to cut the inner boot small clip off and allow it to slide along the shaft towards the gearbox to avoid over stretching the inner boot as I tighten the bolts holding the shaft to the gearbox. I worry that one day I will hit a pot hole and the shaft will pull out of the cup bolted to the gearbox. Thank you Steve.

[Chrispb]

The drive shaft does appear short when suspension is hanging (wait off suspension)

[oldlegs]

Yes thanks for the reply, the 1st drive shaft I fitted I could see the boot was stretching as I tightened  the bolts and thought it would be ok once there was weight back on the wheel but within a couple of weeks I could see the tell tail signs of grease around the inner cv joint and sure enough it had been pulled apart. I really would to sort these few problems out, all the grandkids fit in it, I can even get my motor bike in the back by replacing the front wheel with a barrow wheel and 2 push bikes upside down one at each side of the motor bike and then our caravan on the back. Thanks Steve.