Issue with HBM gearbox rattle , Audi A3 1.6FSI

[Andrei Ionut]

Hi
The last few months I had a rattle that comes from the gearbox/clutch which disappears when clutch pedal is pressed.
The rattle is continuous and various metal noises are present.
After taking the car to mechanic, they said is the gearbox that makes the metallic rattle. I changed gearbox with one from another car( used) and also new clutch.
But..the noise is still present at a lower level.
Could these manual 6 speed gear box HBM have all a problem? I studied and it seems a lot of VW/Audi owners with this manual gearbox experience this rattle which is supposed to come from input shaft bearings.
Have you got any experience on this? Should I recondition the old gearbox? Or is a common problem for all?
Thank you and sorry for long post.

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[Crasher]

Could you private message me your VIN please?

[Andrei Ionut]

Ok, sent.
I forgot to say the diagnostic of faulty gearbox was made on assumptions because no one wants to open a gearbox and it is cheaper to get a used one.
I tried to find if the noise could come from other moving parts but there is no other part it could rattle/ diesel noise from that area.

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[Crasher]

The HBM code box is of the 0AG series so did you fit the later clutch parts as per the Technical Product Information Notice 2038417/1?

Your engine computer is 03C 906 056 CP so it does not look like an update is required.




Technical product information

Transaction No.: 2038417/1



Rattling/grinding noises from manual gearbox - A3 1.6 FSI with 0AG, 0AF

Release date: 23-Sep-2014




Customer statement / workshop findings

A3. 1.6 FSI with 0AG, 0AF gearbox

Rattling/grinding noises at idle speed from manual gearbox especially after cold start. When the clutch pedal is pressed or a gear selected, the noises cannot be heard.
Technical background

Engine vibrations are transmitted via the input shaft into the gearbox and cause disengaged gear wheels to resonate. When the vehicle is stationary and at idle speed, slightly grinding, rattling noises can be heard.

The noises do not indicate any damage, are not related to wear and diminish as the gear oil warms up. At high outside temperatures this effect will be still there, it is just no longer audible. When the clutch pedal is pressed and the vehicle stationary, the input shafts do not turn and are therefore noiseless, and when a gear is selected the gear wheels are engaged and cannot rattle.

Production change from vehicle identification number WAUZZZ8P67A089500

- Clutch pressure plate with other diameter
- Release bearing
- Clutch plate with modified damper friction

Measure

On vehicles before this vehicle identification number and in case of justified customer complaint, replace clutch release bearing, clutch pressure plate and clutch plate according to the parts catalogue. The Parts Department only supplies improved parts.

Replacing the gearbox does not fix the complaint.

In connection with the new clutch the stratified charge must be converted to homogeneous operation.

From 01.05 chassis number 8P 5A 105000 all A3 with 1.6 FSI and 2.0 FSI engines are in the homogeneous operation mode.

First of all, update the software in the engine control unit.

For the 1.6 FSI engine with the engine control unit software with part number 03C 906 056 AP use the SVM code 8P01A015. Then decode the stratified charge as follows:

1. Select self-diagnosis 01 engine electronics
2. 11 coding II, input 10011
3. 10 adaptation of channel 15 (homogeneous lean), channel 16 (stratified operation outside idle speed), channel 17 (stratified operation at idle speed)

The respective release temperature is determined in the individual channels. By changing the basic value to 255 the respective operation mode is decoded.
For the 1.6 FSI engine with the engine control unit software with part number 03C 906 056 AE use the SVM code 8P01A009. This automatically decodes the stratified charge. The individual adjustment channels cannot be selected.

[Andrei Ionut]

Hi and a big thank you.
I replaced clutch kit - pressure plate, disk and bearing Sachs available on the supplier, I assume they only sell updated parts( it is 220 mm diameter).
The problem is that the noise is getting louder when the car warms and lower when is cold. So is somehow different from what bulletin states.
I made a video, engine warm after 20km and the noise is high:
24 iulie 2019 - YouTube (https://youtu.be/wsFrJmFpoSc)


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[Crasher]

Check the part number of the gearbox end cover, if it is 02U 301 201, change it with the five times revised version 02U 301 201 F, these are £166.64 in the UK but I don't know their price in Roumania.

[Andrei Ionut]

Ok, I will search for that. It is sold as a new part? I can't seem to find it on online shops by the code.
The code is in the outside of this cover to take a look?
One final question:
Other than the noise, it does damage and the gearbox could fail if I continue driving it? I have to go in vacation in a few days..that's why I changed everything on the car.
My mechanics say they don't know what else could be done, I now have 2 gearboxes with identical issue...I hoped the noise is generated by other parts.
Thank you for your support.

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[Crasher]

It is just annoying, converting to a dual mass flywheel would help. The part is available from any VAG group main dealer.

[Andrei Ionut]

Wow, I didn't know there is a dual mass conversion for petrol 1.6FSI.
I will ask the local VW dealer.
So there are two solutions as I see:
- replacing back cover of gearbox with fifth revision.
- upgrading to duall mass clutch.
In the mean time, mechanics talk to a specialist who said could do a gearbox reconditioning for 100 Euro + parts which could be costly, in 1-2 days. This is the third solution but don't know if it will solve the problem.

Will look into that, Crasher thanks again mate, very helpful, these informations are not available anywhere else.

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[Crasher]

Sorry, I mislead, the part is the gearbox end cover. For a DMF conversion I would have to do some thing but I guess it is possible.

[Crasher]

How can he do a recon for 100 Euro when the end cover unit is at least double that? These people who say they can recon gearbox's cheaply are lying, a proper rebuild costs hundreds of £'s in parts alone never mind hours and hours of labour, cleaning etc.

[Andrei Ionut]

Yes, I know. He said 100 euro only for labour + cost of the parts.
Anyway, I will think of it.
In the mean time , today the mechanic put some Liquimol Mos2 additive in the gearbox and after 30km there is a slight reduction of the noise.


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[Jdb246]

Crasher I've got same problem grinding noise only happens when clutch is engaged to biting point. Mines an a3 8p 2.0tdi sline quattro. Getting new clutch kit fitted tomorrow. But in neutral no noise, put in gear try for biting point and noise starts. U think I'm doing the right thing getting clutch fixed.? Sorry if this is wrong place to ask

[Crasher]

I hope it works as taking the box out of one of those is an awful job, HUGE lump.