Problems after new clutch install

[ArranFR]

Hello all,
since my local friendly garage fitted a new clutch to my 2005 Leon FR tdi, there have been some mysterious issues. They've had the car back twice to resolve but have been so far unsuccessful. They won't charge me for the labour of fixing, but they can't seem to decide on the cause.

The problem is, since the clutch change sometimes the gears will jam in either 1st or reverse (when reversing). Only way to get back into neutral is to switch off the engine or stall it. Also, the engine will sometimes slightly engage even when in neutral. So when sitting in traffic, in neutral the car will start to pull forward a bit.

The mechanics noted that the clutch pedal lifts a little when slowing down, which may be part of the problem. In order to prevent the gearbox jamming in 1st when approaching a roundabout, its necessary to change to neutral before slowing down.

Garage mechanic suspected the vacuum pump as the old one was pulling a weak vacuum, but after replacing with a new one, the problem remains. Also, the other day I noticed that the revs increased a bit when changing gear, tho not sure if that is a related issue or not.

Any suggestions would be very much appreciated, thanks.

 

[sockpuppet]

Sounds like the slave cylinder to me, this is inside the housing they remove to replace the clutch. I would guess they damaged it in some way when replacing the clutch.

 

[ArranFR]

Many thanks sockpuppet, I'll pass this on to the garage mechanics for when I get the car booked in again asap.

 

[hondated]

I have just posted a query about Torque Steer and how I think it might be caused by the garage not replacing an engine mount shim and now I am wondering whether this could also be your problem.
My logic is that if the engine isn't mounted right surely it could through other things out of line.
Just a thought but I hope that it helps you to solve the problem.

 

[ArranFR]

Update on this problem.
New clutch failed earlier this month, after only 8 months, new clutch fitted (same type as previous was still on warranty). Exact same problem after fitting the new clutch, when in traffic slowing down to a standstill, the gearbox jams in first and is engaging slightly (pulling the car a little forward). Does it nearly every time. The only way to get it into neutral is to switch the engine off.
I thought I'd found the problem when it appeared the clutch switch wasn't secured properly, but that doesn't appear to be the problem. I took the switch out, tested it and it appears all okay. After refitting correctly, the problem remained. Same as before.

Other than that, the car appears to drive fine.

For some reason, the clutch won't properly disengage when slowing to a standstill. Will also jam in reverse.
The new last two clutches are made by LUK, and have been assured they are correct for this car.

Has anyone seen this problem before or have any suggestions? The mechanics are stumped.

 

[hondated]

Hopefully you saw my previous post Andi have been remiss in not informing everyone on what the problem was . I took it back to the garage and after test driving it it was found that the mechanic had left one of the bolts undone securing the gearbox. Like me the garage owner wasn't too pleased but after tightening it the problem was solved. Could this be your problem too !. I also read that if the gearbox isn't fitted exactly as it was this too can cause problems.Good luck.

 

[ArranFR]

Hi hondated, thanks for your feedback. I'm not sure if a missing bolt could explain these symptoms over 2 separate clutch installs, but I'll definitely pass this on to the garage, thanks!

 

[ArranFR]

I just phoned the garage, they're saying no way, as the bolts have all been out and back in twice so they are quite sure there aren't missing bolts. I'm thinking its maybe hydraulic related, either a valve, slave cylinder or something there isn't right.

 

[hondated]

Hi hondated, thanks for your feedback. I'm not sure if a missing bolt could explain these symptoms over 2 separate clutch installs, but I'll definitely pass this on to the garage, thanks!

Thanks Arran just hope you get problem solved for little cost.

 

[spudboy6]

Not sure what box you have 02m ?
The selector fork rivet breaks up and the fork comes loose , I had this exact issue on my 1.8T , went to reverse into my parking space but couldn’t get it out of first until I switched it off ,

Cracked gearbox open and the rivet was broken on the selector , removed rivet refitted it with a nut and bolt and been fine since

May be your issue as sounds like what mine used to do

 

[ArranFR]

Thanks, its becoming a nightmare now. The last time my other half broke down, she spent from 7:30 to nearly midnight at the side of the A12 awaiting AA rescue....

There must be a clue in the symptoms, when the car is moving it changes gear fine, but its just when coming to a standstill (such as in traffic) the clutch doesn't disengage properly. So one way around (when possible) is to change gear when moving, into neutral then coast to a standstill, instead of downshifting as one normally would, that works. And will change into first no problem when moving again.

 

[ArranFR]

Not sure what box you have 02m ?
The selector fork rivet breaks up and the fork comes loose , I had this exact issue on my 1.8T , went to reverse into my parking space but couldn’t get it out of first until I switched it off ,

Cracked gearbox open and the rivet was broken on the selector , removed rivet refitted it with a nut and bolt and been fine since

May be your issue as sounds like what mine used to do

Thanks Spudboy, will check it out ASAP!

 

[spudboy6]

Here’s the pics of when I stripped it to inspect and fix.

May not be your fault but it’s exactly what happened to mine which sound similar to your problem but only way to inspect is dismantle

Google wheeler dealers Audi TT , they repair this fault on the show was only on few nights ago


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[ArranFR]

Thanks again!

 

[Gaz20VT]

So the clutch is dragging? When the garage replaced the clutch, did they replace the thrust bearing or the slave cylinder?
Doesn't sound like a gearbox issue - if the shifter fork had broken it would be either stuck in gear or unable to select a particular gear (like the Wheeler Dealers case).

 

[spudboy6]

When mine failed it went to reverse into my parking space and it got stuck between neutral and reverse , got it into reverse with engine off then reversed and went to move forward some deal again , it eventually fully fell off which was followed by a lot off crunching noises

As I say may not be the issue only my ten pence


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[Gaz20VT]

Wow, that's unlucky for it to fail in just the right (or wrong!) position!

 

[spudboy6]

It was mixed emotions .
Happy to be on the drive ,
Upset because I had just driven from the workshop where I was now about to be towing it back too .




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[ArranFR]

Greetings all, the problem appears to have been fixed. In case anyone finds this thread and has the same symptoms, this is how we got it sorted.
It turns out, the dual mass flywheel was vibrating (it came supplied with the clutch) and was causing contact with the clutch plate. I can only assume it wasn't balanced correctly by the manufacturer. Not only was it faulty, but so was the replacement they sent out. Swapping out the dual mass for a solid flywheel seems to have completely fixed the problem. What a nightmare its been, just glad its sorted (touch wood!).

In all fairness the clutch supplier, LUK, has covered the labour (and cost of solid flywheel) and honored their warranty obligations.
Thanks everyone for your help, all suggestions helped us in the end to get to the solution!

 

[Zardoz]

Sorry to hear you had such trouble with your gearbox / flywheel. Had to have both mine replaced earlier in the year too (LUK) also had to source a replacement gear box shortly afterwards All good now though *touch wood*