Fly wheel and Clutch replacement?
Posted 04 October 2007 - 03:01 PM
Posted 04 October 2007 - 03:11 PM
Posted 04 October 2007 - 03:30 PM
Posted 04 October 2007 - 03:43 PM
Regarding the 2 year warranty... I'm dubious. "Oh, the clutch is worn sir. It's normal wear and tear so not covered by warranty." /ubbthreads/images/graemlins/crazy.gif
Posted 04 October 2007 - 05:06 PM
Posted 05 October 2007 - 06:46 AM
I understand LUK flywheels are half the price VW charge. (VW were charging £125 for the complete clutch assembly a couple of years ago for the 2002 Sport 130 TDI.)
Posted 05 October 2007 - 04:00 PM
Posted 05 October 2007 - 05:19 PM
Edit: I'm not a clutch guru, but it does sound like clutch vibration which would be the flywheel.
Posted 06 October 2007 - 09:54 AM
Posted 10 October 2007 - 07:39 PM
I have a 2002 Passat Sport TDI 130 Estate, bought at 23months old with 58k. The Clutch started to judder only when cold but not on every cold morning. As it was under manufacturers warranty VW agreed to replace the clutch on condition that if it proved to be worn and the cause of the judder, I would have to pay for the labour which was quoted at £325 (2004)
The clutch was unworn and the dealer informed VW it was good for a further 60K so there was no charge. However I did suggested to them that it was more likely the judder was the dual-mass flywheel wear and that it would be prudent to replace the flywheel while it was all dismantled. VW refused but agreed to fit a new flywheel if the problem persisted.
Some weeks later again on cold mornings I had judder. The dealer had it in overnight, agreed the problem was still there and replaced the dual-mass flywheel at VW's expense.
The car has now covered 102k and again judders on start-up on certain mornings exactly as before.
I have posted this symptom before but will repeat as I have found the answer from a conversation with LUK Technical.
On certain mornings condensation will build up on the flywheel for the same reasons that a cold bottle of milk from the fridge will quickly be covered with condensation in a warm humid room. This condensation together with slight wear in the dual-mass flywheel bearing causes the judder. As soon as the flywheel is warm and the clutch friction material is dry the clutch works OK.
I have found this to be the case every time and am grateful to the LUK Technical advisor who first noticed the problem when he previously worked for Rover.
Allowing the clutch to judder will do added dammage to the whole assembly so just slip it a little to burn off the moisture and you will find the problem has gone. I find I can go for weeks in the summer with no judder and even when we have a week of we weather have no judder. It is just those mornings when the flywheel is cold from standing overnight, the air is moisture laden, the temperature changes and it condenses on to the colder flywheel. The advisor said that the problem became frequent when asbestos was removed from the friction material.
Last night was warm here in Wales, the car was covered in 'dew' this morning, the clutch juddered on take up but no further problems all day. My daughter has our 1994 Passat GL Estate TDI with original clutch (non dual-mass) that has now covered 203K so it this judder is due to dual-mass with wear in its bearing.......zzzzzzzz!
These symptoms do not seem to correspond with yours so I would seek further advice before having the whole lot replaced. Have you had the brake fluid changed as it should be every two years AND did you also bleed the clutch hydraulics at the same time? I would do a complete change of fluid before you start on the clutch.
Posted 11 October 2007 - 10:40 AM
Posted 11 October 2007 - 06:53 PM
Reading your symptoms again and bearing in mind that you have only had the car for 2k miles;
'Notchy Gear Change'. The 6-speed box is notchy compared with the 5-speed I had in my previous 1998 TDi sport Estate.
'Lots of vibration noise in lower gears'. There a many parts under the bonnet including the engine cover, pipes etc on bulkhead that can create lots of vibration and noise. Try pressing on many of of these components on tickover and secure with cable ties. Check also the undertrays and clips etc which are often missing. Replace the engine cover mounting rubbers anyway.
'Vibration through gear knob and clutch pedal'. Have the engine/gearbox mounts checked. Has the car been accident damaged at the front and not had the engine mounts replaced?
Was the car like this when you bought it as you have only covered 2k? Is there no comeback with the seller? Let me know how you get on.
(Incidentally, we had rain and mist overnight yet I had no judder this morning as conditions weren't right for condensation!)
Posted 23 October 2007 - 07:20 AM
Posted 23 October 2007 - 07:34 AM
I had this problem,and it got worse and worse until it became really hard to get into gear and used to shake like crazy on tickover.
One flywheel later and haven't once had the problem re-occur.When my mechanic removed the old flywheel you could see just how worn the rubber was.
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