clutch replacement needs new dual mass flywheel???

[mrobson]

Audi a4 avant 1.9tdi. Clutch is 26k and 2yr 3mnth old. Audi had replaced flywheel and clutch at 92k now at 118k. Twice we couldnt engage gears and had to start it up in gear and bugger about to free it off. These incidents happened to the misses with our 10 month son and once on the M40 with RAC recovery so needed sorting out. Audi wouldnt discuss any possibility of discount outside the warranty until they stripped it so not worth risk of them saying yes its faulty but no we wont pay out.

Took it to local Audi/VW specialist. Said some drag on the clutch (selecting gears with engine running was harder than with engine switched off). Agreed take it apart, look, then possibly replace clutch. they found the spigot bearing disintegrated so said will replace it and replace clutch too.
Few days later asked on progress. Slight judder in first on pulling away needs reinvestigating. Few days later asked again, said the spigot bearing breakup may have damaged flywheel so pay the bill and try it to see if it settles in or pay for new flywheel and they'll cover labour for removal again to do it. They mentioned they removed flywheel to fit spigot bearing which added another 1/2 hour labour.

There was no judder at all before they did this job so anyone knowledgable on the subject got any useful comments? I though judder was from warpage or overheating and would show up before a new clutch was installed. Thanks all. Mark.

[mrobson]

Spigot bearing - means the bearing that locates the gearbox input shaft I think.

[golf tdi 02]

if you need a new clutch then it is advised to replace the dmf at the same time as to save doing two jobs just weeks apart.

[Crasher]

Agreed, there is no way I would change a clutch only on a DMF equipped car. The only course of action now is to pull it apart and do it all over again and that includes the clutch again. These are so much work to do that you should not take the chance of having a problem again.

[mrobson]

thanks, i havent actually collected the car from them yet so was looking for advice as Im not happy to take it with a judder. So are you saying that just by fitting and trying the clutch with the old DMF they've knackered it already?

[Crasher]

Quite possibly and no one in their right mind would chance it.

[Pauloz]

Quite possibly and no one in their right mind would chance it.
Agreed. If you kick off you should be able to get them to cover the clutch too i would have thought? Beginners error not changing both together - or at least not very carefully checking the DMF.

A knackered clutch will take out a DMF pretty quick, and vice versa. If its juddering, its putting undue load through the clutch. It might be juddering because the DMF moving around bent the unidirectional drive straps.....

[mrobson]

Had the car back, clutch judder whilst only slight is unacceptable and worse on uphill starts so it'll go back after bank holiday. Not paid anything yet.

What I'd hoped to discover from someone is why a judder might occur after a new spigot bearing was installed along with a new clutch when it didnt have any judder before?

Remember it was a failed spigot bearing that was the problem causing drag on the gearbox shaft rather than the clutch or flywheel failing but the clutch was changed anyway as the box was out. It had only done 26k as has the flywheel too.

I was told the flywheel was removed to change the spigot bearing and the garage suggests the gearbox shaft may have damaged the flywheel and now it's refitted, it's causing the judder and needs replacing - does anyone know if the spigot bearing goes in the end of the crank or in the centre of the flywheel and does this explaination sound plausable or ********?

Thanks for comments so far.

[Crasher]

The spigot goes in the end of the crank and when it fails it often damages the end of the input shaft but that will not cause judder unless it was wrecked and if it was, they should not have re-fitted the box. If it is juddering and the clutch is a reputable new make then it has a faulty flywheel. I guess they will be pulling it apart again.

[mrobson]

Thanks for your input Crasher.

As it didnt judder before pulling apart, any suggestions why it would judder after fitting a new clutch and spigot and puttting together? Also, do spigots come with clutch kits or are they seperately purchased items?

[Crasher]

The spigot bearing is a separate part. Reasons for clutch judder are many and varied such as contamination of the contact surfaces, a faulty pressure plate or friction plate (which make was used?), damage during assembly from poor friction plate alignment, worn input shaft nose or spigot bearing, incorrect tightening of the pressure plate leading to distortion or failed DMF are the most common reasons.

[mrobson]

Thanks for the overview - I dont know what make the parts are they've used but assume they use a local trade motorfactor. I realise dont have much choice other than to give it back and say fix it please but presumably if the flywheel is buckled they should set up a dial gauge to run on it to confirm that before just fitting one? My confidence in them is dented somewhat.

[Crasher]

One thing, ask them if they removed the flywheel when they replaced the spigot bearing. If they did it is possible they damaged the DMF due to careless removal of the flywheel retaining bolts, especially if they used an air gun.

[mrobson]

Yes they said it would be extra 1/2 hour labour because they had to remove the flywheel to replace the spigot bearing which had disintegrated. This is what I mean when I say if it didnt judder before, then why would it judder afterwards.

[Crasher]

PM me your cars reg and your email address.

[mrobson]

Well it's been back to the garage this week and had a new flywheel and another clutch kit fitted. Guess what,,,, it's juddering just the same. really pee'd off now. Any ideas what else it could be or any comments,,, anyone???

[Crasher]

Not without seeing it.

[mrobson]

Judder is only slight but enough to be slightly annoying. Noticable when pulling away, obviously worse on an incline because under more load. Cost £745 so far.