New clutch and engine rattle on idle, help needed

[smiffy86]

Hi guys,

Clutch went on my 1.9 '04 TDI a couple of weeks ago and I spent all of Saturday replacing it with the help of a friend. Before it went it was slipping and had developed a very prominent rattle when idling (metal on metal).

When we took the gearbox out we could see there had been some contact between a component and the gearbox housing has there was a clear "scratch" mark. Couldnt work out what had been hitting it but assumed this was the rattle I could hear.

The flywheel seemed to be ok so we just replaced the clutch. Put everything back together and everything was fine. 100 miles later and the rattling has returned.

My question is would the flywheel be causing this noise as the clutch is perfect now?

Thanks for any help you can give, it's really appreciated!!

[phil miller]

hi mate it sounds very much like the dual mass flywheel needs replacing, how did you test the flywheel when the box was out? there is a set amount of movement allowed on them but it does deffo sound like yours has gone

[smiffy86]

Thaks for your reply. Yeah I did some digging last night after that post and I have come to the conclusion that we should have replaced it. There was a bit of play in it when we were fitting the clutch, but we hoped it would be ok, clearly not! The thought of stripping the car down again to get to the flywheel is a painful one!

[Cabesy]

Hi -

My 2006 Golf V 1.9 TDI had exactly the same symptoms last week. Took it into an independent VW specialist who has identified this as a problem with the DM flywheel which now has too much play through wear & tear. He's calling back with a firm price but ballpark was about £600.

Question in my mind now is whether this a repair that will be required every 3 or 4 years? Car has done 55K miles and always serviced by VW. If that is the case then I think I'll change car pronto.

[smiffy86]

Depends on how you drive it mate. I got mine at 60k and the clutch was fine. Drove it like a sports car when it isn't one and the clutch went at 83k. When I looked at the clutch it was a mess! My point is, the clutch life is not so much down to the part but the driver. If you want to thrash it, expect to chnage the clutch every 50-60k. If you drive it like an old man (like I am now!) it could last 120k plus.

Experience is just another word for the mistakes we make

BTW £600 is a good price. Part is £250ish and the job is laborious. You have to strip everything out to get to it. Takes hours.

[phil miller]

Depends on how you drive it mate. I got mine at 60k and the clutch was fine. Drove it like a sports car when it isn't one and the clutch went at 83k. When I looked at the clutch it was a mess! My point is, the clutch life is not so much down to the part but the driver. If you want to thrash it, expect to chnage the clutch every 50-60k. If you drive it like an old man (like I am now!) it could last 120k plus.

Experience is just another word for the mistakes we make

BTW £600 is a good price. Part is £250ish and the job is laborious. You have to strip everything out to get to it. Takes hours.

auto data give 3.7 hours to change the dmf, which are our place would be £120 + vat, which in real terms is about 3 hrs 45 mins, if you get the dmf and clutch from GSF they have modified both items, they claim it prolongs the life of the items, time will tell

[smiffy86]

3.7 hours if you have a workshop and all the tools

Good luck Cabesy.

[volvofh]

i have a 2005 golf tdi,when i bought the car i got it serviced by a vw technician,he told me when i picked up the car i needed a flywheel.my car only had 48,000 on er.i got clutch kit,release bearing an dmf out euro car parts for £450.it was a LUK clutch/dmf that came out,i put a SACHS back in,same as what vw use only it doesnt have the vw stamp.you get a years warranty with the parts.it in my car over a year nw,an hasnt gave any problems.my friend has a seat leon,he bought it with 17,000 miles and dual mass rattling like mad.its a crap design.

[phil miller]

3.7 hours if you have a workshop and all the tools

Good luck Cabesy.

which i have , i reakon its still poss on your back in 4 and a half hours, they come apart really easily

[smiffy86]

*UPDATE* - My DMF failed this morning!

Car is being towed home now. At least I now know what I'm doing this weekend