Audi A3 2.0 TDi Sport - Flywheel Recall VOSA

[eimaj12000]

Hi guys,

posted about this elsewhere but thought I'd start a separate thread. Recently bought an Audi A3 2.0 TDi Sport and love the car - it's a different class to the old Citroen/Peugeots I'm used to. Anyway, the car has a slight tapping noise when pressing the clutch recently - I've had a (very good and respected) mechanic friend look at the car and he said that this is a sign of a failure in the DMF/clutch unit.

So, researched on forums and VOSA and found that my VIN number is subject to a recall for the flywheel (which may go on fire apparently). Checked the service history for the car (lots and mostly Audi) and there's no mention of any recall work although other important stuff like timing belt and other faults were done.

Contacted Audi UK and had a reply today stating that they have no record of any outstanding recall on my car (from what I can gather this is often a case of fobbing off and many people have had different answers from different dealers). So I have asked in writing for them to confirm IF the work was actually done previously and if so WHEN so that I can note this for my own records. I've also asked if Audi UK actually ACKNOWLEDGE the recall in the first place (i'm betting no is the answer).

Anyway, if anyone has had this work done any advice info would be appreciated. If I don't get satisfaction I'll try through VOSA. I don't actually have a problem if the flywheel was previously replaced, but if they have had a safety recall and are trying to avoid doing the work then that is just plain wrong.

I'll update here as I go and hopefully if successful it'll help others.

[Crasher]

This is my edited and more easily followed version of the recall information

Recall campaign 13C7 Transaction No.: 2011174/2
Dual-mass flywheel Release date: 09-Feb-2006

Technical background

On some vehicles with 2.0 litre TDI engine and 6-speed manual gearbox within the range of chassis numbers listed there is a possibility that the dual mass flywheel supplied by a particular manufacturer may become damaged due to the configuration of the restrictor passage in the bleeder valve in the hydraulic clutch pressure line. This can happen if the clutch is engaged very abruptly, for instance if the pedal is allowed to spring back by itself. The dual-mass flywheel is supplied by two different manufacturers, but only one is affected by this measure.

Chassis number ranges affected

WAUZZZ8P 5A000164 - 176719
WAUZZZ8P 6A000109 - 024252
WAUZZZ8P 4A064592 - 181532
WAUZZZ8P 5B000002 - 017348
WAUZZZ8P 6B000004 - 003832
WAUZZZ8P 369020490 - 020490

Remedy

On the affected vehicles it is necessary to identify the manufacturer of the dual-mass flywheel and if necessary replace the dual-mass flywheel and the bleeder valve (bleeder connection) in the hydraulic clutch line at the slave cylinder, as described in the Workshop Instructions.

Customer notification

Registered owners of vehicles in Germany will be notified directly by AUDI AG. Vehicles must of course always be checked when they are brought into the workshop, even if the customer was not notified to contact the workshop. Please make sure that all vehicles listed in Service Online/DOSyS/FISH are checked during a service visit. You should also pass this information on to your new and used car sales departments so that any vehicles affected can be inspected and modified if necessary before sale.

Warranty accounting instructions

Criterion: 01 = Check dual-mass flywheel (vehicles with front-wheel drive)
Criterion: 02 = Check dual-mass flywheel (vehicles with four-wheel drive)

Check the system to see if the vehicle is affected by the campaign 13C7, and whether the relevant work has already been carried out. Check for entry in the Service Schedule; make entry if necessary.

Establish identity of manufacturer of dual-mass flywheel; if Sachs, make entry in Service Schedule

Criterion 01

Establish identity of manufacturer of dual-mass flywheel; if LUK and dual-mass flywheel 03G 105 266 AF is already installed; replace bleeder valve in hydraulic clutch pressure line and bleed clutch system; make entry in Service Schedule or Check; establish identity of manufacturer of dual mass flywheel; if LUK and dual-mass flywheel 03G 105 266 AF is not already installed; replace dual-mass flywheel; replace bleeder valve in hydraulic clutch pressure line and bleed clutch system; make entry in Service Schedule.

Criterion 02

Establish identity of manufacturer of dual-mass flywheel; if LUK and dual-mass flywheel 03G 105 266 AF is already installed; replace bleeder valve in hydraulic clutch pressure line and bleed clutch system; make entry in Service Schedule or check; establish identity of manufacturer of dual-mass flywheel; if LUK and dual-mass flywheel 03G 105 266 AF is not already installed; replace dual-mass flywheel; replace bleeder valve in hydraulic clutch pressure line and bleed clutch system; make entry in Service Schedule.

Genuine parts required for affected vehicles with criterion 01 or 02 if dual-mass flywheel has to be replaced

1 x Dual-mass flywheel. Part No. 03G 105 266 AF.
6 x Bolts for dual-mass flywheel M10x1x22.5. Part No. N 906 650 01.
1 x Bleeder valve. Part No. 1K0 721 468,
2 x Seals - 9.25x6.07x1.78. Part No. 02F 141 143 A,
2 x Brake fluid (0.1 litre). Part No. B 000 700 S0,
3 x Hexagon flange bolts, securing gearbox support to gearbox - M12x1.5x78. Part No. N 105 964 01,
3 x Hexagon flange bolts, securing gearbox mounting to gearbox support - M12x1.5x70. Part No. N 105 524 01,
1 x Hexagon flange bolt, securing pendulum support to gearbox - M10x35-PC-SW16. Part No. N 102 048 04,
1 x Hexagon flange bolt, securing pendulum support to gearbox - AM10x75-SW16W. Part No. N 104 548 01,
1 x Hexagon flange bolt, securing pendulum support to subframe - M14x1.5x70. Part No. N 105 580 01,
1 x Bolt with washer for drive shaft (outer) - M16x1.5x80x61. Part No. N 910 406 01, only on vehicles with intermediate shaft on right hand drive shaft:
1 x O-ring, 30x2.5. Part No. 01M 323 255.

Auxiliary items and materials required


Grease G 000 100,
Grease G 000 450 02.

Parts supply

The required replacement parts should be ordered in all cases from your Importer (or regional distribution centre).

Parts despatch control

After removal, parts should be returned in the normal way to the Importers warranty inspection department.

Sample letter to UK vehicle keeper

Re:- Dual-mass flywheel


Recall number :- 13C7
Your Audi A3 with chassis number:- WAUZZZ8P04A??????
Registration:- ???????

Dear Sir/Madam

As a result of the company’s product monitoring, AUDI AG has found that there is a possibility that the flywheel installed in your vehicle (a "dual-mass" flywheel supplied by a particular manufacturer) may become damaged due to the configuration of the restrictor passage in the hydraulic pressure line for the clutch. This can lead to failure of the dual-mass flywheel and in unfavourable conditions may cause a fire in the vehicle. For safety reasons, your vehicle must therefore be inspected. The inspection of the dual-mass flywheel will take about half an hour. Should it be necessary to replace the dual-mass flywheel, this work will take five hours, and will of course be carried out at no charge to you. (In some cases the workshop may need to keep the vehicle for slightly longer). Please contact your Audi partner without delay to make an appointment. Please bring this letter and your Service Schedule with you when you visit the workshop, so that we can make all necessary entries. If you have any further queries in connection with this inspection please contact your Audi partner or call our Service Hotline number 0800-AUDI SERVICE (0800-2834 7378423). We are sure you will appreciate the need for this precautionary measure, and regret any inconvenience caused by the extra workshop visit. If you have sold your vehicle or have taken it out of service, please complete the enclosed reply card and return it to us as soon as possible. Your co-operation will be appreciated.

Yours sincerely,

XXXXXXXXXX

Q&A

What is the problem on the affected vehicles?

The dual mass flywheel may become damaged due to the configuration of the restrictor passage in the bleeder valve in the hydraulic pressure line for clutch actuation. This can happen if the clutch is engaged very abruptly, for instance if the pedal is allowed to spring back by itself. The dual-mass flywheels are supplied by two different manufacturers. Only the flywheels supplied by one of these manufacturers are affected by this problem.

What is the cause of this fault?

The design of the restrictor passage in the bleeder valve in the hydraulic line for clutch actuation.

What effect does the fault have?

After causing unusual mechanical noises, the dual-mass flywheel will eventually fail completely. In unfavourable conditions this can lead to a fire in the vehicle.

Which vehicles are affected by the fault?

The problem affects Audi A3 models with a 2.0 litre. Diesel engine (100 kW or 103 kW) and a 6-speed manual gearbox which were built in the period from October 2003 to June 2005 and were fitted with this particular flywheel.

Is it safe to continue using the car until it can be inspected/repaired?

Yes, you can drive the car until the inspection/repair is performed. If unusual mechanical noises occur in the engine compartment (in area of clutch/gearbox) you should take the vehicle to an Audi partner to have it inspected/repaired without delay.

Have there been cases reported by customers?

Yes, some cases have already been reported.

Is there any risk for the car occupants?

No.

What exactly needs to be repaired on the car?

The dual-mass flywheel of the manufacturer in question will be replaced and the existing bleeder valve in the hydraulic clutch pressure line will be replaced by a new bleeder valve with a modified restrictor passage.

Will the driver be aware that a fault exists?

A defective dual-mass flywheel will first manifest itself in unusual mechanical noises.

How long will the inspection/repair take?

The inspection to determine whether the dual-mass flywheel needs replacing will take about half an hour. Should it be necessary to replace the dual-mass flywheel, this will take approx. five hours.

My clutch is worn out; does this have something to do with the bleeder valve?

No. If the bleeder valve in the hydraulic clutch pressure line is not configured in an ideal manner this has no bearing on the life expectancy of the remaining clutch components. The clutch plate and pressure plate are always subject to wear and must be replaced after a certain mileage has been covered.

Is the customer entitled under the mobility guarantee to receive a replacement car for this inspection/repair?

Not if only the inspection is required. A car will be provided for a maximum of 1 day if the dual-mass flywheel has to be replaced.

Can I have the inspection/repair carried out anywhere in Germany or other European countries?

Yes All Audi partners in Germany and other European countries have been informed.

Is it necessary to make an appointment at the workshop?

Yes, definitely. Your Audi partner will want to make sure that the parts required for your vehicle are in stock.

Technical background

On some vehicles with 2.0 litre. TDI engine and 6-speed manual gearbox within the range of chassis numbers listed there is a possibility that the dual mass flywheel supplied by a particular manufacturer may become damaged due to the configuration of the restrictor passage in the bleeder valve in the hydraulic clutch pressure line. This can happen if the clutch is engaged very abruptly, for instance if the pedal is allowed to spring back by itself. The dual-mass flywheel is supplied by two different manufacturers, but only one is affected by this measure.

Check

If the vehicle is not already listed as repaired in the service system, check the Service Schedule for the entry 13C7 completed. If the entry is not listed, carry out the required work in accordance with instructions.

Work

Identifying manufacturer of dual-mass flywheel by checking shape of flywheel (criterion 01 or 02)

The dual-mass flywheel fitted in the vehicle is supplied by either Sachs or LUK. If you can establish that the vehicle is fitted with a dual-mass flywheel manufactured by Sachs, no further steps are required. However, if you establish that the vehicle is fitted with a dual-mass flywheel manufactured by LUK, it will be necessary to replace the dual-mass flywheel and the clutch bleeder valve if applicable. The two different versions can be distinguished as follows without removing the gearbox:

1) Remove centre noise insulation
2) A number of recesses are located at the bottom part of the sump between engine and gearbox.
3) Check the external shape of the flywheel by visual inspection and by feeling with the fingers through the recesses. A rounded external contour (figure A) = Sachs version clutch/flywheel The Sachs version flywheel does not have to be replaced. A square external contour and groove running all round (figure B) = LUK version clutch/flywheel.

Replace LUK version flywheel
Replace clutch bleeder valve.

On vehicles with Sachs version flywheel the work required for this campaign is now completed. After completion of all required work, make the entry 13C7 completed (including date and workshop stamp) in the Service record section of the Service Schedule or in the section for Workshop remarks.

If the vehicle is fitted with a dual-mass flywheel manufactured by LUK, replace the dual-mass flywheel and the clutch bleeder valve if applicable.

[eimaj12000]

Many thanks for this Crasher - the single, most complete and best post I've seen relating to any recall ! I know it may be a slim chance but I've known of 2-3 instances before now where friends have had recall work done many years later and the previous owners had for some reason missed it. I guess it's ramps time and the most sensible course of action is for me to check the flywheel shape on the car.

Again I'll post my findings. If it does turn out to be an LUK one then you never know - if not then nothing is lost I suppose.

Crasher many, many thanks again for taking the time to post.

Just an aside - managed to check the sticker inside the boot (it's also in the front of the service book) and there's no mention of 13C7 anywhere. As I said tomorrow I'll get underneath the car and just visually inspect the flywheel and cross-check with the data you so kindly provided. At least it's a 50/50 chance of being LUK and I'm betting if it is it's original.

[Crasher]

One thing that could catch you and Audi out if it does have an LUK flywheel is that these are still widely sold and are more common than Sachs. If the car does have an LUK and Audi pull the box out only to find it is a none genuine original or even a later replacement genuine LUK flywheel, they are going to drop a large bill on you so make sure you find out what would happen if this was the case. The recall sticker in the boot is not the large white paper one but a small rectangular sticker and there are often a couple of them.

[eimaj12000]

Hi Crasher,

Very good point - I'll have to be careful with this one. Just wondering - from the information it seems they MUST have had to examine every car visually in those VIN ranges ? So just wondering would these stickers then be put on the car just to say it had been taken in and either cleared as being non-LUK or marked as being LUK and replaced ? So basically if I don't have the stickers at all - does that mean that the car hasn't even been looked at or just that the recall work wasn't done ?

Interestingly enough a rep from Audi UK telephoned today to speak to me regarding this (left a message anyway as I missed the call). I'll let you know how it goes but thanks again - your assistance has been invaluable and whichever way it goes your post on the recall is superb.

[Crasher]

The way I read it is every car in this range, should it go into a dealer, should be checked and sticker applied either way. That's the way I see it anyway.

[adamss24]

take the starter off and try to use a tiny inspection mirror with a light to shine whilst rocking the car in gear to spin the engine. Should be obvious if LUK or Sachs flywheel was fitted...

[eimaj12000]

Thanks guys. Well, have now found out that this HAS been done (from Audi and confirmed by VOSA) so at least that's an end to it. Thanks again for everybody's assistance and information on this. Apparently from what I was told there ARE still vehicles with an OPEN status (i.e. they haven't been checked) so if yours is in the VIN range give Audi a call.

A new clutch/flywheel it is shortly then - from what I can see price is approx. £450 for full kit ? I have a good mechanic to do the work very reasonably for me so labour isn't a problem and he's good with VAG cars having done my old B5 Passat before.

Thanks again to all who posted - it is much appreciated.

[rich080487]

I have an Audi A3 2.0TDi and I have checked the VOSA website and I believe my car is in the VIN range to receive a DMF. I have tried giving Audi a call, but they are adamant that it is not due a recall...

Can anybody suggest the best way for me to progress the situation with Audi or VOSA?

Thanks, Rich