VW Golf MK4 130bhp Dual Mass Flywheel Problems

[Time Dependant]

Afternoon all,
some of you are aware I've posted one or two threads regarding a knocking sound coming from my engine compartment recently, after reading the below thread yesterday it seems that FinngalWay1 was also experiencing the same problems.

http://www.vwaudiforum.co.uk/forum/showthread.php?p=140613#post140613

After engagning my clutch when the knocking noise occured it instantly disappeared and removed any vibration which I was feeling throughout the car, this I believe is one way to determine if your DMF is faulty.

My questions really are:

What is the typical cost associated with having a DMF fixed?
How long would it take to be fixed?
What other symptoms can be felt with this problem?

I've got the car booked into the garage tomorrow is it worth me printing some of the posts on the forum and saying that I believe my DMF is faluty?

[MarcoV]

Im pretty sure its about £1200.

[mluton]

I would say between (Inc labour) £650 - £1200 (as above)

Garage dependant

[bonard]

I would say between (Inc labour) £650 - £1200 (as above)

Garage dependant



HAD MINE DONE IN DECEMBER

DMF...........210 QUID
CLUTCH KIT................98.50
HYDROLIC CLUTCH RELEASE BEARING ...36 QUID
THEN THEY SLAP THE VAT ON WHICH TAKES IT TO £404.79

I GOT A GOOD LOCAL GARAGE TO DO IT THAT WAS £100

[Time Dependant]

Thanks guys I've asked them to check the DMF so rather than spending hours searching around hopefully they can go straight to the source of the problem and resolve it!

I'll let you know the outcome later today

[bonard]

Thanks guys I've asked them to check the DMF so rather than spending hours searching around hopefully they can go straight to the source of the problem and resolve it!

I'll let you know the outcome later today

would this not be a gearbox out job? and how or what would they do to check it?

[Time Dependant]

Just to let you all know that the garage have heard the noise but have said that without stripping out the engine they can't find what's causing it which would make sense.
But the problem I have now is they think the warranty company won't pay out for this work to be done as it's only a noise can anyone suggest what I should do as the garage say that without taking things apart they can't discover where the noise is coming from and I could be hit with a bill for around £1k!

[herby0001]

Yes, you're probably right - insurance companies will squirm out of paying up. If you can find a garage who CAN diagnose the problem first, then you may be in with a chance of getting the leeches to pay for it.

[Time Dependant]

Garage has quoted me 4 hours labor @ £180 for the removal of the gear box just to have a look, to me that seems steep this doesn't involve any work been done.
I'm unfamiliar with what time it takes to remove a gearbox and diagnose a problem I really need some advice as to how much i should pay.

[Kunal]

in the same boat as you mate!!!! need a new clutch and maybe a new dual mass flywheel. i gt my whole thing for £200 approx, which includes the clutch kit AND the DMF from euro car parts. my car is a mk4 115bk. 1999. the garage told me about £400. i'll keep you posted on what they say should be 2day or 2mo. good luck

[Time Dependant]

in the same boat as you mate!!!! need a new clutch and maybe a new dual mass flywheel. i gt my whole thing for £200 approx, which includes the clutch kit AND the DMF from euro car parts. my car is a mk4 115bk. 1999. the garage told me about £400. i'll keep you posted on what they say should be 2day or 2mo. good luck

Do you have experiences of fitting clutches and DMF's yourself? It will probably cost me a third of the price to do it myself but not confident in my skills that I would do a good job.

[Kunal]

no experience at all, just know a lil bit on cars. well i just brought a £200 clucth kit with the DMF and the garage will be fitting it in tomorrow, let you know how that goes on. this is where i got the parts from: http://www.eurocarparts.com/ecommerce/Search_Results.asp hope this helps you.

[Kunal]

sorry with that link scroll down to TRANSMISSION PARTS and the select clucth kits......

[finngalway1]

Just to let you all know that the garage have heard the noise but have said that without stripping out the engine they can't find what's causing it which would make sense.
But the problem I have now is they think the warranty company won't pay out for this work to be done as it's only a noise can anyone suggest what I should do as the garage say that without taking things apart they can't discover where the noise is coming from and I could be hit with a bill for around £1k!
hi again got someone to listen to noise an same as above.. what am i to do????:aargh4:

[Kunal]

the ticking noise, did it come from the front slighty on the right hand side of the engine. but at the bottom? i had that tickin noise aswell. its something gt to do with the clucth or the flywheel.

[Time Dependant]

hi again got someone to listen to noise an same as above.. what am i to do????:aargh4:

Do you have a warranty covering the car? Mine is covered by Car Care Plan who informed me that you can take it to any garage you want as long as there happy to deal with Car Care Plan when making a claim.
I've got a friend who works for a garage so I'm taking it to him this weekend, but he warned me that with these types of warranties that unless something on the car has actually failed the warranty company won't pay out, so if your DMF is slightly warn it's likely they won't sign off the claim and you'll have to drive it until you actually break down, which is a complete load of sh*t as this will probably damage even more of the car meaning more money to be shelled out for work and parts.
My suggestion is go to a local garage you've used before explain the problem and see if they will sign the DMF off as failed so the warranty company pay out, it seems like an expensive job to replace these parts the garage I got recommended to take it to wanted £180 for 4 hours labor just to take the gearbox out, I would have had to pay another £180 for them to put it back in as well and they wanted me to pay to get a specialist in to have a look, yeah right!

I'll update as much as I can hopefully I can ge this fixed on Saturday.

[finngalway1]

the only warranty that i have is with garage i bought it from.. guy that looked at her on fri last told me that if i said it to him that he would probably say it was my clutch ???? which isnt covered by warranty over here...(eire) only have her since nov 07. first the alloys were partly welded and he had it nearly 4 wks before i got her back.. complete with new ones!! had mentioned the noise but it seemed to go over his head????i have a 6 mth warranty on it so am going to bring it to him again even if he says clutch i couldnt have worn that in a couple if months could i????

[Kunal]

rite, gt call from the garge and she's ready to be picked up tomorrow!!! in total i spent £476.15 with a new DMF and a whole new clucth kit. which i brought from euro car parts. all though they had to order one more part which i cnt remember what it was. which was about £30. i will test drive the car nd keep you posted, hope all this info was good.

[robat282]

slave cylinder? that's really good, my tame mechanic has quoted me £600 to do mine all in, he's sourcing the parts tho...

definatly let us know how you get on!

[Pauloz]

Garage has quoted me 4 hours labor @ £180 for the removal of the gear box just to have a look, to me that seems steep this doesn't involve any work been done.
I'm unfamiliar with what time it takes to remove a gearbox and diagnose a problem I really need some advice as to how much i should pay.
Removing the gearbox is 95% of the way to changing the clutch, and the only way to check the clutch. 4-6 hours is the norm unless theyre a clutch specialist whoc could do it in a 3rd of the time....

[Pauloz]

the ticking noise, did it come from the front slighty on the right hand side of the engine. but at the bottom? i had that tickin noise aswell. its something gt to do with the clucth or the flywheel.
A DMF knocks more thn ticks, and is more noticable on engine shut off as it bounces around after the crank has stopped.

[tornadored7]

Hi Paul,

So what form of abstract art is a clutch / DMF ? ;)
Vivid colours particularly the Thai / Phucket pictures!

TR7

[Pauloz]

Hi Paul,

So what form of abstract art is a clutch / DMF ? ;)
Vivid colours particularly the Thai / Phucket pictures!

TR7
:biglaugh: aye, some sherman dreamt DMF up years ago.
funny you should say that though - I'm currently working on a large abstract of a clutch for the reception of a clutch manufacturer ;)

[finngalway1]

am noy sure what do do about the noise u can actually hear a nearly """clacking noise""more in middle of car!!! garage that sold it to me is not giving me any faith in which to ask him to fix it....

[Pauloz]

am noy sure what do do about the noise u can actually hear a nearly """clacking noise""more in middle of car!!! garage that sold it to me is not giving me any faith in which to ask him to fix it....
Well, IMO, its either the DMF, or gearbox bearing. Both expensive jobs to fix. If gearbox, it could last like that a long time before going spectaculary and costing much more. If DMF its likely to deteriorate quickly.

[finngalway1]

ya i think i will be out of pocket again!!!!:( have you any idea of best to phrase this to dealer and is it covered under a warranty????:1zhelp::1zhelp:

[robat282]

so a rattling coming for the front of the car, somewhere in the middle of the dash when gears are engaged could be gearbox bearing?

[Pauloz]

ya i think i will be out of pocket again!!!!:( have you any idea of best to phrase this to dealer and is it covered under a warranty????:1zhelp::1zhelp:
Dont mention the word 'warranty' to start with - and let them know that you understand that they didnt make the DMF, but 'have the manufactures of the dmf acknowledged an issue' or similar. Use the phrase manufacturing defect rather than warranty ;)
It could be either a sachs or LuK unit on here incidentally.
If they blame driving style, ask them how. The correct answer is either slipping the clutch/holding on the bite point too long/driving with foot on the clutch pedal and therefore heating the DMF up too much. Or possibly driving in too high a gear for the road speed - but id fall off me perch if they knew that one :biglaugh:

[finngalway1]

rite, gt call from the garge and she's ready to be picked up tomorrow!!! in total i spent £476.15 with a new DMF and a whole new clucth kit. which i brought from euro car parts. all though they had to order one more part which i cnt remember what it was. which was about £30. i will test drive the car nd keep you posted, hope all this info was good.
yeah thanks

[Arge]

I've had what sounds like the same problem on my mk4 golf...rattling / vibrating / clunking noises when the car is engine braking, that quiet down when you engage the clutch.

I had my mechanic take it for a drive and he said it was a noisy differential, which is a sign that its on the way out. i thought i'd get a 2nd opinion so took it to a gearbox specialist yesterday - he immediately recognised the noise and basically said that the differential bearings and pinions need replacing. to cut a long story short he is going to rebuild the differential for £250 (thats a days labour and parts), however thats excluding removal and refitting of the gearbox.

It might be worth you doing something similar - i.e. see a gearbox specialist. if you do have this problem then you have one of three options:
1. buy and fit a brand new gearbox...about £1500 - £2000 (VW's quote, fitted)
2. buy a second hand or reconditioned gearbox...about £300 - £600 + fitting
3. get your box rebuilt...as above (but don't know how cheap / expensive that quote is as its the only one i have)

hope this helps.

[Crasher]

Arge, your car has on 02J 5 speed box which is a completely different design to the 02M 6 speed box which isn’t prone to diff bearing problems, but then again neither is the 02J!

[Arge]

ok - must have missed that somewhere when i was scanning through the thread...just thought it might be useful as it sounds like a very similar problem.

[finngalway1]

hi ,,,,ill certainly look into that option...nobody i bring it to seems to give me a definate response about what it could be.. dealer said is not covered under my warranty!!!!!!!:zx11:i think when these people see me coming try to fob me off with any old remark... (partly due to me being female):o.....have checked out prices for flywheel on euro-parts and i would save a lot that way.if it is the flywheel... some say like urself gearbox bearing, or flywheel,.. i dont want to go to more added expense if im replacing something which i dont have to... ireland is expensive enough, i feel like am being taken for a bit of a fool really...:mad:

[tdi_power]

I have done countless amounts of DMF replacements on Golfs because as soon as they get a little warm from clutch slip etc the internal wading melts and causes the unit to become unbalanced and fall apart internally. They are a very common fault and is a relatively labour intensive job as the box is not easily removed. You could enquire into fitting a steel flywheel as it would be a cheaper unit and would prevent the same occurance in the future.

[bonard]

A DMF knocks more thn ticks, and is more noticable on engine shut off as it bounces around after the crank has stopped.


this is exactly what mine did, the sound also seems to go when you press the clutch in. This is how mine was diagnosed for a replacment DMF.

If the DMF has to be replaced is it not wise to do the cluch plate and release bearing at the same time?

[Crasher]

If the DMF has to be replaced is it not wise to do the cluch plate and release bearing at the same time?

Not just wise, stupid not to.

[finngalway1]

Garage has quoted me 4 hours labor @ £180 for the removal of the gear box just to have a look, to me that seems steep this doesn't involve any work been done.
I'm unfamiliar with what time it takes to remove a gearbox and diagnose a problem I really need some advice as to how much i should pay.



any updates????

[vwray]

i`ve done alot of reserch into the same problem with my dual mass, and i was told to get a ordinary clutch and flywheel becouse the problem will keep orcuring depending on how you drive and miles you do, but where do i get one for my gt 130 i`ve no idea.

[Crasher]

ECP sell the kits but I would not advise it, there is quite a significant loss in refinement-in my opinion. The latest batches of new DMF's seem to be holding up very well. I have never had a repeat failure-yet.

[peggy]

hi i am a tech in a skoda gge on older cars with dmf has siezed up this will make it rough we fit a complete replasment clutch flywheel kit this is about £250 for the kit then about 4 hrs labour.

[finngalway1]

hi i am a tech in a skoda gge on older cars with dmf has siezed up this will make it rough we fit a complete replasment clutch flywheel kit this is about £250 for the kit then about 4 hrs labour.



garage here have quoted me around 650-700 euro for flywheel and clutch plate,, would i be better off getting one myself and giving to them???? might save some cash... but dont know what i need....

[Crasher]

You may save a few Euros but doing that is a really good way to seriously 91ss a garage off! Would you take your own bottle of wine to a licensed restaurant to save a few Euros?

[finngalway1]

You may save a few Euros but doing that is a really good way to seriously 91ss a garage off! Would you take your own bottle of wine to a licensed restaurant to save a few Euros?

ha ha.....:approve: they have her now anyway!!!!
ill probably have to sell my soul instead. . .

[Time Dependant]

any updates????

Hi Finngalway,
If I'm honest I'm still driving the car as it was before. I found out that the warranty company will only replace the DMF if it's actually broken not if it's on it's way out.
My Golf seems to be falling apart at the moment I'm now getting a whirring noise from the rear of the car almost under the back seats but it can only be heard inside of the car, also performance is lacking big time in the lower gears.

[finngalway1]

i know how you feel!!! mine just got louder and louder as well:aargh4:
bit the bullet so to speak yesterday and gave her in to be fitted, worse for the car to be left like that to be honest. have spent too much money on her toto pay for it myself as its not covered under my warranty either, also have to get my

cv joint done, relay and regulator.... costly but it will be worth it;)
not sure about ur knocking noise could it be your suspension????
ill keep you updated on outcome of cars operation ok

[finngalway1]

You may save a few Euros but doing that is a really good way to seriously 91ss a garage off! Would you take your own bottle of wine to a licensed restaurant to save a few Euros?

point taken.... :Blush:

[Time Dependant]

i know how you feel!!! mine just got louder and louder as well:aargh4:
bit the bullet so to speak yesterday and gave her in to be fitted, worse for the car to be left like that to be honest. have spent too much money on her toto pay for it myself as its not covered under my warranty either, also have to get my

cv joint done, relay and regulator.... costly but it will be worth it;)
not sure about ur knocking noise could it be your suspension????
ill keep you updated on outcome of cars operation ok


Have you had it fixed yet?

[finngalway1]

its in at the moment.... should have her back mon or tue... will keep you posted

[cheesman22]

hi people, just joined and staight away everyone has the same problem as me , my dmf is going as well , i have just changed the cluch only to find the dmf has play in it , been givin a price @300 quid just for the part.:zx11:

[Time Dependant]

hi people, just joined and staight away everyone has the same problem as me , my dmf is going as well , i have just changed the cluch only to find the dmf has play in it , been givin a price @300 quid just for the part.:zx11:

Hi Cheesman22,
I feel your pain it's not a cheap job to complete depending on the garage you got to you'll be quoted between £750-£1000 for the work to be done. It's crazy how expensive and common this problem is and it's one that unfortunately has to be fixed otherwise you will get hit with various other bills due to additional damage that can be caused if the DMF fails.

I've managed to get my friend at the garage to do a sneaky one with the warranty company to say my DMF has completely failed otherwise they won't replace it, so I'm hoping I will have all of my work done free of charge. As I've still got a month left to run on the warranty I feel I should get something out of it seeing as I've paid for it!

Mines going in this weekend

[cheesman22]

hi mate , well i hope they pay for so they shud, ive just found out today that my rear mount has completely snapped off , great an extra thing to pay for , as regards to the dmf i have just changed my clutch a week ago and the dmf only comes with a clutch , do u knw were i can only buy the dmf,thanks:zx11:

[Kunal]

chessman22. i feel your pain aswell mate, had mine go last month.......apprently evry1 one on this forum siad it would cost about £1000 on average. but i gt mine done from MR CLUTCH for £420 inc labor and parts, all the garges get their parts from eurocarparts, on there website for a clutch kit and a DUAL MASS FLYWHEEL £300.so i gt that and told them to fit it in!!!! but u'v a;ready changed the cluch! but the garge should of told u that the DMF is on its way out.

[Pauloz]

Hi Cheesman22,
I feel your pain it's not a cheap job to complete depending on the garage you got to you'll be quoted between £750-£1000 for the work to be done. It's crazy how expensive and common this problem is and it's one that unfortunately has to be fixed otherwise you will get hit with various other bills due to additional damage that can be caused if the DMF fails.

I've managed to get my friend at the garage to do a sneaky one with the warranty company to say my DMF has completely failed otherwise they won't replace it, so I'm hoping I will have all of my work done free of charge. As I've still got a month left to run on the warranty I feel I should get something out of it seeing as I've paid for it!

Mines going in this weekend
Warranty with who bud? Main dealers? The aftermarket warranty on DMFs is lifetime...... against manufacturing defects. Dealers is normally 2 years.
Neither will really listen too anything an independant garage says in my experience - inspecting the part will tell them everything..... if they know what theyre looking at ;)

[Time Dependant]

Warranty with who bud? Main dealers? The aftermarket warranty on DMFs is lifetime...... against manufacturing defects. Dealers is normally 2 years.
Neither will really listen too anything an independant garage says in my experience - inspecting the part will tell them everything..... if they know what theyre looking at ;)

Aftermarket warranty mate with Car Care Plan, I called them to understand how I can make a claim they said only parts which have completely failed will be covered, wear & tear is not covered.

[Pauloz]

Aftermarket warranty mate with Car Care Plan, I called them to understand how I can make a claim they said only parts which have completely failed will be covered, wear & tear is not covered.
Ok, I have no experience dealing with them. But your DMF will have a manufacturers warranty too - is it the OE part fitted from new or bought since?

DMF wear is usually down to wear and tear unforunately mate - but how your warranty company looks at DMF normally will have set the precidence. doubt they'll include any fact in the descision as they wont know what theyre looking at anyway ;)

[Time Dependant]

Ok, I have no experience dealing with them. But your DMF will have a manufacturers warranty too - is it the OE part fitted from new or bought since?

DMF wear is usually down to wear and tear unforunately mate - but how your warranty company looks at DMF normally will have set the precidence. doubt they'll include any fact in the descision as they wont know what theyre looking at anyway ;)

It's the original DMF which was fitted with the car as far as I'm aware, it's only an 03 plate which is worrying.
When I took out the warranty I was given a breakdown of what was/wasn't covered the sheet which I've looked over covers things like:

DMF
Clutch Plate
Bearings

Only if they've failed due to manufacturer failure hence gettting my friend so say it's a dodgy part.

I'm hoping it will just be some young girl in a call centre who doesn't understand cars & just signs it off

[Pauloz]

It's the original DMF which was fitted with the car as far as I'm aware, it's only an 03 plate which is worrying.
When I took out the warranty I was given a breakdown of what was/wasn't covered the sheet which I've looked over covers things like:

DMF
Clutch Plate
Bearings

Only if they've failed due to manufacturer failure hence gettting my friend so say it's a dodgy part.

I'm hoping it will just be some young girl in a call centre who doesn't understand cars & just signs it off
I'd hope so too bud - but you could be pushing it. The DMF doesnt last for 5 minutes if its made wrong to be honest as its such a critical element in an extremely harsh environment, let alone since 03.
Good luck!

[Time Dependant]

Just to let you all know I had the work done on a DMF & clutch replacement, my DMF had alot of play in it (around 8mm), so I've had the DMF replaced along with cluth plate, clutch cover. clutch release bearing, and clutch slave cylinder.
The car is driving beautifully now it seems to pick up speed in the lower revs alot quicker and the vibration I was getting throughout the car at 2,000rpm seems to have dropped off.

The only thing for me to do now is claim back the £898.58 it cost me to get sorted!!!!!!!!!!!!!

[cheesman22]

hi chaps, time dependant im glad u got it done and hope u get ur cash back , mines really bad now , and im glad that u said urs happens at 2000 rmp , cos so does mine as i was thinking that it might be a engine mounting , is there much of a difference after its been changed.thanks:biglaugh:

[Time Dependant]

hi chaps, time dependant im glad u got it done and hope u get ur cash back , mines really bad now , and im glad that u said urs happens at 2000 rmp , cos so does mine as i was thinking that it might be a engine mounting , is there much of a difference after its been changed.thanks:biglaugh:

Thanks Cheesman22,
I would strongly suggest biting the bullet & getting it done I know it's expensive but if it goes you're looking at a bill over £1k for other repairs which the clutch caused due to failing.
I left mine for about 2-3 months before I pushed to get it repaired but I had the following symptoms which may help in locating the exact problem:

1). On engine start up when cold a knocking noise would develop from the rear of the engine, this would last for about a minute and would make the car shake quite badly.

2). The only way to remove the knocking noise would be to engage the clutch, as soon as you disengaged the clutch the knocking noise would re-appear.

3). Around 2,000rpm the car would feel like it was sticking, there was no smooth acceleration again a vibration through the steering wheel would be felt. I changed the MAF thinking this had failed but my old one was actually ok so now I have two.

4). When coming to a stop and switching the engine off the car would shake badly.

I've only driven the car once and that was this morning into work which for me is an hour journey into Southampton so I got to test it out on various road surfaces (motorway, country lanes, city roads etc) and it feels 100x better.
The car seems so much more responsive and nimble when I put my foot down, also the clutch is really light making gear changes a breeze.

My advice is either call around several garages and get them to quote a price, or buy all the parts required and ask them to fit it.

I feel your pain buddy your not alone!!!

[Pauloz]

Just to let you all know I had the work done on a DMF & clutch replacement, my DMF had alot of play in it (around 8mm), so I've had the DMF replaced along with cluth plate, clutch cover. clutch release bearing, and clutch slave cylinder.
The car is driving beautifully now it seems to pick up speed in the lower revs alot quicker and the vibration I was getting throughout the car at 2,000rpm seems to have dropped off.

The only thing for me to do now is claim back the £898.58 it cost me to get sorted!!!!!!!!!!!!!
Glad you got it sorted mate! However 8mm is a little on the low side for movement to be honest - although depends how that was measured. 10-15mm free play including spring compression by hand is normal ;)

[cheesman22]

cheers mate , u shud be a mechanic , ur symptons are exactly the same as mine , ive just organised a repair this weekend , i got the flywheel for 184.00 and 100.00 labour , let u knw how i get on thanks.:approve:

[Pauloz]

cheers mate , u shud be a mechanic , ur symptons are exactly the same as mine , ive just organised a repair this weekend , i got the flywheel for 184.00 and 100.00 labour , let u knw how i get on thanks.:approve:
I hope youre changing the clutch as well bud?

[cheesman22]

yeah mate i changed it last week , and since then thats wen i noticed the dmf .

[Pauloz]

yeah mate i changed it last week , and since then thats wen i noticed the dmf .
Cool. But get the clutch checked VERY carefully before its put back on; a knackered DMF can damage a clutch in several different ways.

The segments can fracture immediately inside the friction lining where the outer ring attaches to the centre - so check for cracks.
Also check the rivit holes in the friction lining that attach both sides together - if theyre at all oval, it shouldnt be re-fitted.
Both the above because the DMF wont be damping effectively - and the added vibration cant be absorbed by the plate as there are no spring in it when a DMF fitted (most of the time) so its literally shaken to bits.
Also the tangential straps need to be checked for kinks. These are the 3 uni directional drive straps that connect the pressure plate with the cover - with the DMF bouncing around they can be subjected to reverse torque and kink, which will mean the clutch wont clear properly and quickly deteriorate. They should have a smooth gentle curve. No step at all.

Hope that helps bud ;)

[cheesman22]

ok cheers for that mate , but it was last sunday so it shud be ok rite???

[Pauloz]

ok cheers for that mate , but it was last sunday so it shud be ok rite???
Should be alright - but to be fair it can only take minutes. Your last clutch was knackered for a reason remember......

[robat282]

Mines in today getting its new DMF/Clutch/Release bearing, should get it back later and looking forward to a changed car! In total it's costing £500 parts and labour! I bought the sachs clutch & dmf kit which you can get from Euro Car Parts for £220+vat and the slave cylinder from www.vwspares.co.uk which cost £36+vat.

[Time Dependant]

Mines in today getting its new DMF/Clutch/Release bearing, should get it back later and looking forward to a changed car! In total it's costing £500 parts and labour! I bought the sachs clutch & dmf kit which you can get from Euro Car Parts for £220+vat and the slave cylinder from www.vwspares.co.uk (http://www.vwspares.co.uk) which cost £36+vat.


Sounds like I got done on the price then:zx11:

[finngalway1]

well finally got car back.... 3 weeks they had it
put in new stainless flywheel and clutch , so far noise is gone although i dont want to listen too hard. i think it would push me over the limit if i did hear anything,, they still didnt fix the silly faults relay, regulator etc but hey i gotta put this one down to my total stuipidity and realise i got done... big time... total cost 985.00 euro:zx11::zx11:..another thing timing belt was done on her @ 75,000 miles so he said, its on 97,000 at the minute just wondering when it would be due again???

[Pauloz]

well finally got car back.... 3 weeks they had it
put in new stainless flywheel and clutch , so far noise is gone although i dont want to listen too hard. i think it would push me over the limit if i did hear anything,, they still didnt fix the silly faults relay, regulator etc but hey i gotta put this one down to my total stuipidity and realise i got done... big time... total cost 985.00 euro:zx11::zx11:..another thing timing belt was done on her @ 75,000 miles so he said, its on 97,000 at the minute just wondering when it would be due again???
Youve got another 50k on the timing belt then bud.
985 Euro is a good deal in my opinion!

[finngalway1]

nice one cheers,hopefully everything should go smoothly now,,, been too long without her!!!:beerchug: thanks for the help on this one, thought id never see the end of all this... great forum by the way:drive: thanks from an irish colleen

[cheesman22]

hello everyone , i got my dmf and new clutch done and its done the trick , and i got it at a snip , 200 quid for both , bargin

[Time Dependant]

hello everyone , i got my dmf and new clutch done and its done the trick , and i got it at a snip , 200 quid for both , bargin


Good work glad everyone has got there's sorted!!

[finngalway1]

hi guys am back again...:zx11: noise is back same as before:aargh4::aargh4: what has happened?????

[dieselman580]

Hello all,

Just picked up my MK4 Golf Tdi 130. On tick over it has a slight vibration, if i push the clutch pedal it goes. Has anyone else had a similar problem?
Will it get any worse or will it stay like this?
Thanks

Rob

[Crasher]

Does the engine rock back and forth?

[dieselman580]

hello mate, not checked if engine rocks, what does it mean if it does
thanks rob
ps what could cause it does the fly wheel go of balance?

[finngalway1]

well ithink flywheel either wasnt fitted properly or was never flyheel in the beginning!!! remember someone said at the start of all this is could be either --flywheel trouble or clutch release bearing--trouble still there im out of pocket by nearly a grand and none the wiser..noise is coming from down under gearbox( i think)like a shuddering clacking noise more noticeable on first start of the day dont seem to hear it after that but more cos i dont want to hear it:aargh4:

[dieselman580]

hi yes it does rock but put clutch pedal down and it stops

[finngalway1]

:(
Does the engine rock back and forth?
mine does.... lifted bonnet on one occasion and engine cover was rocking

[dieselman580]

just noticed it only does it when engine is cold, once its at running temp its fine

[finngalway1]

ive been totally scanked on this!!1 paid out 980euro for a flywheel 2 mts ago and its happening again now

[Crasher]

Yes, that is classic flywheel failure.

[dieselman580]

i see ok, will it stay like that, and just do it when its cold then?
thanks rob

[dieselman580]

ive been totally scanked on this!!1 paid out 980euro for a flywheel 2 mts ago and its happening again now


hi mate, so you had a new flywheel fitted and its doing it again?
also does your engine rock and does it only do it when cold?
as soon as mine is at running temp its fine.

[finngalway1]

check this out its very similar to mine keawe had posted this




http://smg.photobucket.com/albums/1003/Matt.H/VW%20Golf%20GTTDI%20150/?action=view&current=P1000569.flv

[dieselman580]

check this out its very similar to mine keawe had posted this




http://smg.photobucket.com/albums/1003/Matt.H/VW%20Golf%20GTTDI%20150/?action=view&current=P1000569.flv


yeah mine rocks aswell, but as i say soon as its at running temp its fine

[Crasher]

It will steadily get worse. A customer sent me to check out a Golf 4 GT TDI 130 that he had his eyes on. Apart from the fact it was a Basis model import that had been badged as a GT TDI (some people are so unscrupulous) it rocked at idle and improved markedly when hot but I told him it would only get worse.

[dieselman580]

It will steadily get worse. A customer sent me to check out a Golf 4 GT TDI 130 that he had his eyes on. Apart from the fact it was a Basis model import that had been badged as a GT TDI (some people are so unscrupulous) it rocked at idle and improved markedly when hot but I told him it would only get worse.


i see, so within time it will start doing it when its hot?
and the only cure is a new flywheel?

thanks rob

[Crasher]

Yes, if it is the DMF.

[dieselman580]

isee, so if i have a new flywheel fitted have they been uprated or modified to resolve this problem?? is this the sort of milage they start to go around the 60k mark?also how much am i looking at to get a flywheel, and clutch fitted?
thanks rob

[Crasher]

The units haven’t been upgraded as far as I know but I haven’t had a repeat failure yet. As for cost, that varies wildly depending on who does it (man in a shed up to main dealer, huge variation in labour) and where the parts come from. Aftermarket is much cheaper than genuine but they don’t have the same warranty cover. It depends on how you want it doing, what your priorities are and how much you can afford.

[Time Dependant]

Just to let people know I had my DMF replaced when I originally posted about this problem, it seemed to cure the symptoms for about 2 weeks but am now experiencing the knocking sound which originally occured which led me to believe it was the DMF on it's way out.
The knocking sound will begin whenever the engine is cold on startup & seems to have got worse, as it makes the car shake & the engine move quite considerably.
I'm thinking I may have a loose engine mount as i've had the DMF & new clutch kit fitted but still no cure.

Also the performance in the car feels restricted, it's almost like driving with the brake on sometimes.

I had it on the diagnostic unit 4 times with no fault codes showing, but I know that this is not how the car was when I originally bought it back in Dec 07.

Any suggestions?

It seems to be a common theme surrounding the 03 GT TDi 130bhp models of this Golf in particular, I'm surprised there is no offical VW stance on this.

[Crasher]

There is a solution from VAG outlined for this under technical bulletin 2001578/3. If there are no codes stored and if the flywheel is new, a poor idle during warm up may mean you need a new ECU with upgraded software but I would need to know the software version installed to tell you if the updated software is relevant to your car. Do you have a fault code report? This may show the data version of your software which should be 5259.

[Time Dependant]

There is a solution from VAG outlined for this under technical bulletin 2001578/3. If there are no codes stored and if the flywheel is new, a poor idle during warm up may mean you need a new ECU with upgraded software but I would need to know the software version installed to tell you if the updated software is relevant to your car. Do you have a fault code report? This may show the data version of your software which should be 5259.


I'll have a look tonight on the invoices I was given back. Would the poor idle cause the knocking sound though, I would assume something is coming loose?

[Pauloz]

I'll have a look tonight on the invoices I was given back. Would the poor idle cause the knocking sound though, I would assume something is coming loose?
It could be the DMF being overstretched by rough running - the knocking could be the DMF hitting its internal stops.

[Time Dependant]

It could be the DMF being overstretched by rough running - the knocking could be the DMF hitting its internal stops.

When you say rough running I guess this goes back to Crashers mention on the ECU possibly been faulty causing poor idle from start up.

Do you know rough costs for a new ECU? I'm expecting it to be big bucks.

I'm considering selling the car altogether I've had nothing but trouble with it in a 6 month period what's happened to Golf's!!

My little brother has an Audi A3 1.6 for sale so I may snatch that insteaad.

[finngalway1]

When you say rough running I guess this goes back to Crashers mention on the ECU possibly been faulty causing poor idle from start up.

Do you know rough costs for a new ECU? I'm expecting it to be big bucks.

I'm considering selling the car altogether I've had nothing but trouble with it in a 6 month period what's happened to Golf's!!

My little brother has an Audi A3 1.6 for sale so I may snatch that insteaad.

mine just the same time dependant, new flywheel fitted and clutch kit. same noise as urs after 2 1/2 wks!! i am so despondant with all of this i cant even think about where to go next,

[finngalway1]

I'll have a look tonight on the invoices I was given back. Would the poor idle cause the knocking sound though, I would assume something is coming loose?


yeah the whole engine rocks on mine.....

[Crasher]

An A3 1.6 less trouble than a 130PD, now that would be something!

[finngalway1]

hey all, back again.....
update on everything ongoing... noise as i said in my last post had returned after 2 or so weeks, was so sickened, firstly as i had to pay
for it myself as the garage wouldnt cover under warranty,
and then for noise to return :mad:
i didnt go near them for a while as i was too blooming angry to look at them, returned it to them 2 wks ago and they sent her to a vw garage up country which came back that there was nothing wrong with the clutch
and was something about the ECU car came back ,, no noise so far!!!!
(touch wood):arms:
BUT there is now something wrong with 2nd gear on the car, when ever esp when cold , i find it very difficult to put her in second gear without a little bit of force. brought car back AGAIN last fri, where mechanic poked
around under the bonnet and sprayed something down by the gears and it felf fine for a bit, but am finding it harder to put into 2nd all the time whereas the rest of the gears are fine 6 speed gearbox , any ideas???

[stubbsy]

no experience at all, just know a lil bit on cars. well i just brought a £200 clucth kit with the DMF and the garage will be fitting it in tomorrow, let you know how that goes on. this is where i got the parts from: http://www.eurocarparts.com/ecommerce/Search_Results.asp hope this helps you.
id love to no where your getting these prices from:D ive been pricing myself the past few weeks as my clutch is on its way out:( the cheapest i can get is from gsf, clutch £96 plus vat, dmf £200 plus vat = £296 plus vat for a complete clutch and dmf and thats trade;) all to fit an ajm engine which has a 240 mil clutch:approve:

[paradoxni]

I appear to have the same problem.

I have a golf TDI 130, would someone point me to the correct parts I need to replace clutch and DMF.

On euro car parts:
DUAL MASS FLYWHEEL GOLF 1.9TDI VW GOLF MKIV 1.9TDI 05/00- £160.95
CLUTCH KIT GOLF 4 BORA A3 SHARAN £117.40#

£327.06 inc vat??

is this all thats needed? do these parts require youre old parts to be returned to euro car parts?


EDIT having put in the correct model in eurocarparts they now have:

FLYWHEEL WITH CLUTCH G4/BORA/A3 VW/ £184.95 + VAT

will this contain everthing thats needed or will I need the clutch release bearing etc. as well.

[Crasher]

That is the price for a 5 speed DMF and clutch.

[Time Dependant]

HI Finngalway1,
I was just seeing how you're getting along with your car since you had the ECU replaced? Mine is still in the same state as before so really just driving it with around 50% performance lost I would say.
Still no faults showing up when I take it to garages so it could be this?

Does anyone know how much a new ECU would cost for the following:

VW Golf GT TDi
03 Plate
130 Bhp




hey all, back again.....
update on everything ongoing... noise as i said in my last post had returned after 2 or so weeks, was so sickened, firstly as i had to pay
for it myself as the garage wouldnt cover under warranty,
and then for noise to return :mad:
i didnt go near them for a while as i was too blooming angry to look at them, returned it to them 2 wks ago and they sent her to a vw garage up country which came back that there was nothing wrong with the clutch
and was something about the ECU car came back ,, no noise so far!!!!
(touch wood):arms:
BUT there is now something wrong with 2nd gear on the car, when ever esp when cold , i find it very difficult to put her in second gear without a little bit of force. brought car back AGAIN last fri, where mechanic poked
around under the bonnet and sprayed something down by the gears and it felf fine for a bit, but am finding it harder to put into 2nd all the time whereas the rest of the gears are fine 6 speed gearbox , any ideas???

[Crasher]

Between £860 and £875.

[Crasher]

£700 inc. DMF from VW is extremely cheap fitted, it doesn’t add up as that is parts only. You don’t know if it is Sachs or LUK until it is out but usually they are LUK.

[bonard]

£700 inc. DMF from VW is extremely cheap fitted, it doesn’t add up as that is parts only. You don’t know if it is Sachs or LUK until it is out but usually they are LUK.


credit crunch prices bet they cant get the work in quick enough... it is very cheap tho I would probably have it done by them for that price .. my flywheel clutch and hydrolic bearing cost me over 400 from GSF then 100 for a local garage to fit.. its all ok saving a bit of cash .......but then the garage that did it for me I bet you they would not offer as good service if anything went wrong after? worth thinking about for 200 quid

[ak_wf1]

No i wish it was 700 fitted, thats just for the parts!!!!

Ta for your help lads.

[Crasher]

Yes, that is about right genuine, you could save a bout £200 buying the parts from Sachs or LUK but you only get a 1 year parts warranty, not a 2 year parts and labour.

[bigcheese2017]

HI could anyone help me please my clutch has droped to the floor what could this be? And would i need to replace the intire duel mass and clutch kit please?? Thankyou in advance

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[micheal balbrig]

Check the pedal first,sometimes the welds break causing similar problem.

[bigcheese2017]

Ive checked the pedal but cant see anything noticable

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[bigcheese2017]

I can upload some pics later if this will help anyone help me cheers

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[Crasher]

Does the pedal lift back up cleanly and start working again only to drop to the floor again later; or is it basically stuck to the floor? The white plastic clips similar to below can burst through its box on the pedal due to failure of the folded over retaining tag, which is welded on replacement pedals



http://i222.photobucket.com/albums/dd20/Crasher1964/Sachs6K2721401A.jpg

If this is what has happened, the master cylinder pushrod will also be bent but in my experience this does not matter and has no effect on its operation, you just need a new pedal, clip and clutch pedal switch operating pad, the latter often gets forgotten and causes running issues when changing gear.

33557

[bigcheese2017]

It stoped working i can pull it up but as i go to press it bam straight to the floor

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[Crasher]

Does it feel rough as you move it or smooth?

[bigcheese2017]

Feels smooth and kinda stiff when pulled up then a lil tap makes it spring back to the floor so cant ingage it into gear https://uploads.tapatalk-cdn.com/20170709/9d6cab40602c0c0f36274428f098843c.jpghttps://uploads.tapatalk-cdn.com/20170709/84c95741dbff1b2efa7fbafd1baa4419.jpg

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[Crasher]

If the pedal breaks you get a little square piece of thick steel on the floor followed by a few white plastic fragments so from what you say it sounds like a hydraulic failure. It is very difficult to differentiate between a failed master cylinder or slave cylinder (concentric release bearing in the 02M 6 speed box) but normally if it is release bearing failure, lifting the clutch pedal up will sometimes make it work again for a while, so the symptoms you describe sound like master cylinder failure and certainly it is what I would try first.

[bigcheese2017]

If i change the master cylinder do i habe to change the hole cluth?

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[bigcheese2017]

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[Crasher]

The clutch master cylinder is on the bulkhead, that and you asking me the second question I find quite alarming if you are going to be working on the car.

[bigcheese2017]

Ignore the second question and the clutch master cylinder is diffrent to the brake master cylinder so ignore that queation

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[Crasher]

If changing the master cylinder does not make the clutch function again then it will be a problem with the release bearing or clutch pressure plate, either way the box has to come out so you would be remiss in not changing the full clutch and DMF when in there.

[bigcheese2017]

Alright thats for the advice i will to buy a hole clutch kit and have the full thing changed whats your opinion on dmf replacements? Are they any good

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[Crasher]

I won't fit a solid flywheel conversion on a TDI unless the customer signs a disclaimer over the downsides such as gearbox rattling, vibrations and increased fuel consumption. I would not take the box out until I had tried a new master cylinder.

[bigcheese2017]

Are you a machanic from nottingham ? If so how much would it cost your garage to fit if i suplied the master?

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[Crasher]

Yes an independent VAG specialist in Nottingham since 1988 and we are now registered with VAG Germany as a recognised independent repairer. We are not keen on fitting other people's parts for a number of reasons such as if it doesn't fit the whole thing turns into a sketch, I doubt we could not match the price for the correct quality part you could get anyway as we are not just a VAG specialist garage but also an international parts supplier to trade and retail. PM me your reg number and I will find work out some costs for you tomorrow BUT we are short staffed at the moment due to holidays and illness. If you already have the MC then no problem.

http://www.candrenterprises.co.uk (http://www.candrenterprises.co.uk/)

Items in Audi Seat Skoda VW Volkswagen Parts store on eBay ! (http://stores.ebay.co.uk/audiseatskodavwvolkswagenparts)

[bigcheese2017]

yh its Ov03 jdk vw bora 1.9TDI PD150 thanks

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[Crasher]

I could supply a new Febi master cylinder fitted and bled for £150.

[bigcheese2017]

Whats a febi master cyclindwr that name of it?

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[Crasher]

Febi is the brand. febi United Kingdom | Home (http://www.febi.com/febicouk/home.html)

[bigcheese2017]

You able to come out to fit the part as it not driveable wilst the.cluych the way it is

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[bigcheese2017]

Are you

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[Crasher]

No, we only work in the workshops.