grahamb Posted May 14, 2005 Report Share Posted May 14, 2005 OK, Audi A6 2.8 30V Quattro, 1998, 97000 miles on the clock. Developed noise from gearbox 5000 miles ago. My Gearbox man now has the box out, and has discovered so far: New clutch New main shaft bearing New main shaft (Quattro has a special hollow main shaft with another shaft running inside it) New clutch release bearing (it fell apart when the box was taken off the engine) And wait for it . . . the dual mass flywheel needs replacing, and he dreads to think how much thats going to cost from Audi. So, Monday, I get the bill (he said he didn't want to ruin my weekend) Any guesses on the total cost? (+£450 labour excl VAT) Link to comment Share on other sites More sharing options...
danksy Posted May 14, 2005 Report Share Posted May 14, 2005 £2k all in? Link to comment Share on other sites More sharing options...
cruiser647 Posted May 14, 2005 Report Share Posted May 14, 2005 Sorry to hear that. Hope it is not too much! Any ideas as to why it might have gone wrong? Link to comment Share on other sites More sharing options...
grahamb Posted May 15, 2005 Author Report Share Posted May 15, 2005 The oil had apparently broken down inside the box, which would account for the bearing failure. I'm not sure what the service interval is on oil, but it didn't look in too good a condition. As for the flywheel, who knows? I have a huge amount of mechanical sympathy (i build and race cars) so I don't think its how I've been driving her. Also she's had 5 previous owners (in the 5 years prior to me owning her) so I dont know the history of useage. I have fitted a tow bar and covered 6000 miles with the trailer on the back, but again, would this cause a flywheel to fail? I reckon it'll be around £2500 all in. I'll have to keep it for another 100,000 miles to get my money back (thats if the engine lasts that long without requiring a rebuild) Link to comment Share on other sites More sharing options...
danksy Posted May 15, 2005 Report Share Posted May 15, 2005 Flywheel failure is very rare! Heavy clutch dumps may hit the plates together, but more likely it wasn't up to scratch to start with! mmm I suppose it could have been caused by a bodged clutch replacement some time ago?! Anyway at least she'll be good for another 100k miles like you said !! Link to comment Share on other sites More sharing options...
cruiser647 Posted May 15, 2005 Report Share Posted May 15, 2005 I dont think I have ever had to change the gearbox oil on a manual car. Not the sort of thing ever done is it? Auto - yes, but manual - no!!! Have you ever changed the gearbox oil in your XR2 racer? Link to comment Share on other sites More sharing options...
Smiddy Posted May 16, 2005 Report Share Posted May 16, 2005 I know BumpRT just had a new gear box in his A8 4.2QS he said that was around 3K so I dont think you are far off with a 2.5k guess there. But i think his was a new gear box you should have a look in the A8 forum. Link to comment Share on other sites More sharing options...
grahamb Posted May 17, 2005 Author Report Share Posted May 17, 2005 Got the bill! All plus VAT Flywheel £611 Clutch kit (incl release bearing) £180 Main shaft bearing £114 Main shaft tube £440 The killer now is that the main shaft tube has to be sourced from Germany and is on a 10-14 day lead time. Another fortnight without my A6! (sob) Total cost incl labour and VAT is £2139 +- a few quid. Link to comment Share on other sites More sharing options...
Edd_W Posted May 20, 2005 Report Share Posted May 20, 2005 flywheel with a new one, I would just get a standard flywheel off an old 100 2.8. The end of the crank is the same and you end up with a smoother gear change and no worries if you do like dumping the clutch. I think the old one broke down probably because of oil leaking fron the crank oil seal so make sure a new one is fitted, also the valley pan and cam adjusters leak and the oil can end up going down onto the flywheel. If you do decide to fit a solid f/w then make sure the depth is the same as the dual mass-one. You may need a different drive and cover plate as well. Get the one for the engine your solid f/w comes off - ie AHA series. With regard to the box, I would just find another box, providing you match the code on the top of the bell housing the diff will be the same ratio. You would probably find a q box for about £300 to £400. Link to comment Share on other sites More sharing options...
grahamb Posted May 20, 2005 Author Report Share Posted May 20, 2005 Trouble is getting a clutch to fit apparently. Also no joy on getting a 2nd hand Quattro box, the manual 5 speeder is rarer than hens teeth, and besides, most likely find it'd be just as knackered (if not more) than my box was. My engine had no oil leaks. It was probably due to either my spirited driving, or contamination from the clutch more than anything else. Interesting to read that the DMF should be replaced whenever a 2nd replacement clutch is fitted anyway... http://www.sachshandel.de/owx_medien/media141/14172.pdf Link to comment Share on other sites More sharing options...
andyo Posted May 23, 2005 Report Share Posted May 23, 2005 The clutch on the A6 is on its way out and after a few calls for prices the local Audi dealer said don't let it slip otherwise the bill will probably include a new flywheel. Link to comment Share on other sites More sharing options...
Edd_W Posted May 25, 2005 Report Share Posted May 25, 2005 phone number at work, I'm at home today. Link to comment Share on other sites More sharing options...
grahamb Posted May 26, 2005 Author Report Share Posted May 26, 2005 OMG ! The gearbox place has said that the car is ready, so I'm off down south tomorrow to pick it up... Sniff, its been over 3 weeks! Link to comment Share on other sites More sharing options...
grahamb Posted May 27, 2005 Author Report Share Posted May 27, 2005 Drives like new now, no noises, sweet as a nut. Should be good for another 100,000 miles. I'll post picks of the broken bits up soon as... Link to comment Share on other sites More sharing options...
cruiser647 Posted May 28, 2005 Report Share Posted May 28, 2005 Good news Mr b. Link to comment Share on other sites More sharing options...
grahamb Posted May 30, 2005 Author Report Share Posted May 30, 2005 Here are two photos of over £1300 of parts. Knackered dual-mass flywheel. £611 +VAT Knackered main shaft tube from the Quattro box. £440 +VAT The moral of the story. 1) You cant do anything about the flywheel deteriorating. Chances are, 100K miles and you'll also need a new one. And if its the 2nd replacement clutch, you'll need a new one anyway. 2) Change your gearbox oil regularly. The gearbox specialist said the oil in my box had 'broken down' and therefore wasn't offering much in the way of protection. I'd say, based on his experience, the oil should be changed every 50,000 miles on the Quattro box. Ignore at your own peril. I'm going to get the rear diff oil changed as soon as, as thats also long overdue changing. Audi have not published any change intervals for the A6 Quattro box. For some reason they assume the oil never needs changing. WRONG! My next mods are a B&M short shifter for shorter gear changes, a cone filter, and a decent high flow stainless steel system using some Dynomax powerflow cans. Should sound sweet. Link to comment Share on other sites More sharing options...
Ian_C Posted June 11, 2005 Report Share Posted June 11, 2005 [ QUOTE ] You cant do anything about the flywheel deteriorating. Chances are, 100K miles and you'll also need a new one. [/ QUOTE ] You've just put me right off a (B5) A4 Avant 2.8 quattro. Sorry for the hassle you suffered! Ian Link to comment Share on other sites More sharing options...
Chrisg Posted June 13, 2005 Report Share Posted June 13, 2005 I think some of the boxes no longer have drain plugs. I've always worked on the basis that a few £££ of oil was cheap insurance ! Well worth doing the rear diff, from memory about 2 litres of oil. Link to comment Share on other sites More sharing options...
grahamb Posted June 14, 2005 Author Report Share Posted June 14, 2005 And now a cat has failed, and both would have been removed when the gearbox was repaired. I guess they either weren't as gentle with them as I hoped, or I'm just damn unlucky Total repair bill this year alone will soon be over £2550 . . . Link to comment Share on other sites More sharing options...
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