Possible Gearbox issue

[Rajsta]

A6 2L TDI s- line, Engine:caha. Gearbox:Hck. 127000 miles.
Genuine oil always used.

Note: These issues happened with my previous clutch as well as my new clutch.

The things I'm noticing are-
A rattle when clutch is depressed.
Car is always juddery when moving off.
Slight vibration in gearstick.
At Random times I cannot put it into 1st without pumping the clutch and wacking it into gear.
Excessive Clutch smell when driving spirited ie overtaking on motorway (not racing).

So this issue was on the old and new clutch.
Could anyone suggest anything? Dodgy input shaft? Driveshafts? Etc

[Crasher]

Was a new DMF fitted with the clutch and which make of clutch was fitted, LUK or Sachs and who did the work?

[Rajsta]

Was a new DMF fitted with the clutch and which make of clutch was fitted, LUK or Sachs and who did the work?

The old set was Luk flywheel and Sachs clutch. The new one is all Sachs performance.
The old set was fitted by McEwans Garage in Derby. The new set by Michael Key Garage in Nottingham.

[Crasher]

Sachs Performance? The EXTEND type or SPORTING? Is it a solid flywheel conversion?

[Rajsta]

Sachs Performance? The EXTEND type or SPORTING? Is it a solid flywheel conversion?

It's not the Extend type.
It's sold as Sachs performance, I think the difference is the reinforced clutch cover.

Clutch cover (reinforced) 883082.001424
Friction plate 881864.001707
Dmf 2294002198
Release bearing 043151271937

[Crasher]

The cover and disc are what they used to call "Sporting" and the cover is interchangeable with VAG OE number 06C 141 117 whilst the disc is interchangeable with quite a few OE numbers so I need you to PM me your VIN.

[Rajsta]

The cover and disc are what they used to call "Sporting" and the cover is interchangeable with VAG OE number 06C 141 117 whilst the disc is intecghnable with quite a few OE numbers so I need you to PM me your VIN.

Pm sent

[Crasher]

I will leave that unread in my inbox as I am upto my balls in **** tomorrow

[Crasher]

The clutch system parts for yours are

Part	OE	Sachs	LUK	Sachs Performance
DMF	03G 105 266 BH	2294 501 178	415 0244 10	None listed
Friction disc	03G 141 031 P	not shown	not shown	881864 001748*1 or 881864 001707*2
Pressure plate	078 141 123 C	not shown	not shown	883082 001424
Release bearing	01E 141 165 D	3151 271 937	500 1050 10	043151 271937
Clutch kit	078 198 141 D	3000 951 872 (Xtend)	624 3342 00	NA
Needle bearing	06B 105 313 D	1863 869 047	410 0139 10	1863 869 047
Flywheel bolts x 6	N 906 650 01	411 0133 10	411 0133 10	411 0133 10
Pressure plate bolts x 6	N 910 654 01	NA	NA	NA
Guide sleeve	01X 141 180	NA	NA	NA
Guide sleeve bolts x 3	N 903 663 01	NA	NA	NA
Clutch lever	01X 141 719 B	NA	NA	NA
Ball pin (upgraded)	0B1 141 777 A	NA	NA	NA
Intermediate piece	012 141 751 C	NA	NA	NA
Retaining spring	012 141 741	NA	NA	NA
Spline grease	G 000 100	NA	NA	NA

*1 rigid disc sintered lining
*2 rigid disc with organic facings

The Sachs Performance catalogue (page 141 https://aftermarket.zf.com/remotemedia/master-content/mc-sx/products-2/products-pc-lcv/performance/performance-pdf/sx-cat-ebook-performance-clutches-12338-v01-201606-in.pdf) does not list a special DMF for yours. In my trade look up list the Sachs flywheel 2294 002 198 is just a normal flywheel equivalent to the VAG 03G 105 266 AT but this was replaced by the 03G 105 266 BH in 2008 and that is a Sachs 2294 501 178 which became the 2294 002 198 listed above. Personally I feel the choice of the 881864 001707 disc hard to fathom, I wouldn’t fit that design even it the in full on 3L VR6 turbo I am building, way to nasty for street use.


881864 001707

[Rajsta]

The clutch system parts for yours are

Part	OE	Sachs	LUK	Sachs Performance
DMF	03G 105 266 BH	2294 501 178	415 0244 10	None listed
Friction disc	03G 141 031 P	not shown	not shown	881864 001748*1 or 881864 001707*2
Pressure plate	078 141 123 C	not shown	not shown	883082 001424
Release bearing	01E 141 165 D	3151 271 937	500 1050 10	043151 271937
Clutch kit	078 198 141 D	3000 951 872 (Xtend)	624 3342 00	NA
Needle bearing	06B 105 313 D	1863 869 047	410 0139 10	1863 869 047
Flywheel bolts x 6	N 906 650 01	411 0133 10	411 0133 10	411 0133 10
Pressure plate bolts x 6	N 910 654 01	NA	NA	NA
Guide sleeve	01X 141 180	NA	NA	NA
Guide sleeve bolts x 3	N 903 663 01	NA	NA	NA
Clutch lever	01X 141 719 B	NA	NA	NA
Ball pin (upgraded)	0B1 141 777 A	NA	NA	NA
Intermediate piece	012 141 751 C	NA	NA	NA
Retaining spring	012 141 741	NA	NA	NA
Spline grease	G 000 100	NA	NA	NA

*1 rigid disc sintered lining
*2 rigid disc with organic facings

The Sachs Performance catalogue (page 141 https://aftermarket.zf.com/remotemedia/master-content/mc-sx/products-2/products-pc-lcv/performance/performance-pdf/sx-cat-ebook-performance-clutches-12338-v01-201606-in.pdf) does not list a special DMF for yours. In my trade look up list the Sachs flywheel 2294 002 198 is just a normal flywheel equivalent to the VAG 03G 105 266 AT but this was replaced by the 03G 105 266 BH in 2008 and that is a Sachs 2294 501 178 which became the 2294 002 198 listed above. Personally I feel the choice of the 881864 001707 disc hard to fathom, I wouldn’t fit that design even it the in full on 3L VR6 turbo I am building, way to nasty for street use.


881864 001707

Thanks, I appreciate the info.
Regarding the friction plate, I chose that variant as it states it is good for taxi use! I don't find it particularly hard to use apart from the as mentioned issues. Are you saying the friction plate is contributing to the issues