Golf 2.0 FSI problems

London · Post by **London** » Mon Aug 01, 2011 2:19 pm

Hey guys. My car has been standing for almost a month before I took it for a drive last week. I made a topic before about the oil leak I had on it, VW dealer who did my service before the leak didnt wanna take responsibility for it, they checked it and gave me a diagnosis that the oil filter housing needs to be changed and it will be about R2200 to replace the housing. I continued driving like that monitoring oil level regularly. Anyway, I finally parked the car when one day driving from Midrand going to PTA on N1, I really struggled to change gears. To take it out of gear was a mission and to put it in another gear was a problems as well. I nursed it till I got home and I parked it.

That gave me enough determination to start working on it. I started with the oil leak problem. I started ripping the front of the car to get access to work on that stupid placed oil filter housing

. I had to remove almost all components in the front. I took some pichers which ill upload when I get the chance. I was disgusted at VW when I finally took out the housing, there was no crack what-so-ever that I could say oil would leak from, instead, there was a very good sign that it actually leaked from the oil pressure switch which it would have taken me about 10min to fix. I also know that it was my fault for not doing my own diagnosis, I took their word for it and went straight to the job

. Anyway, it was good for experience and I fixed it, no more leak.

Now for the real stuff, the gear change problem. First thing I did was to bleed the clutch line, I've done that for days, trying different techniques, convensional method, recirculating method from brake caliper bleed nipple, home made power pressure method, well after I decided that i've bleed it enough, I now could get gears and I could drive the car. The problem was that when I press the clutch and keep it there, I heard and felt some vibration on the pedal, if I release the pedal a little bit, the noise disappears. When I move from the line, it was doing the same thing but once moving, it was fine and I could change gears with one exception, when I hammer it, I could not change at all, it just blocked me from selecting any gear until the revs dropped to about 2000rpm then it would go in. Then eventually it got stuck in gear and no matter what I did to the pedal, it was ineffective, it just stayed in gear so I had to drive for about 2km to home in 2nd gear. The pedal does not stay on the floor but its soft. I can change gears when the car is off but once started, its very impossible to change to any gear. The slave and master cylinders are both fine, I took out the slave cylinder and tested to see if there was considerable force when the clutch pedal is depressed, well lets just say I couldnt stop the slave cylinder rod from moving outwards. Any take to what might have happened.

Sorry guys for a very long post, I just wanted to give as much details as possible, I hope im forgiven

Velofox · Post by **Velofox** » Mon Aug 01, 2011 3:56 pm

pressure plate might have some broken fingers..

joggiep · Post by **joggiep** » Mon Aug 01, 2011 4:00 pm

Velofox wrote:pressure plate might have some broken fingers..

Jip... time to take the box out and have a look at the pressure plate.

Velofox · Post by **Velofox** » Mon Aug 01, 2011 4:07 pm

Driving with your foot on the pedal ne

London · Post by **London** » Mon Aug 01, 2011 4:34 pm

Velofox wrote:pressure plate might have some broken fingers..

Did thought about that, but how often does that happen? Instead, i've heard alot about bent or broken clutch forks.

Velofox wrote:Driving with your foot on the pedal ne

Dont like doing that. Even at a traffic light, id rather put in neutral and use handbrake rather that riding the clutch.

Velofox · Post by **Velofox** » Mon Aug 01, 2011 4:41 pm

Let's start off with your mileage then. Driving styles and model

London · Post by **London** » Mon Aug 01, 2011 5:02 pm

The car just clocked 180 000km. Not sure if its on original clutch, it has full service history and no clutch change is reflected anywhere on the book. I guess its on original clutch then. My driving style still leaves alot to be desired. I would say at the least the car sees redline on daily bases. Not hooligan driving though, just 2 or 3 gears taken to red line and normal driving resumes there after.

Velofox · Post by **Velofox** » Mon Aug 01, 2011 5:19 pm

It seems like the cable shift boxes or should I say pressure plate does not like to live long metal fatigue I assume. I'm sure its the pressure plate. I done a Polo gti and it had the same symptoms

London · Post by **London** » Mon Aug 01, 2011 5:29 pm

I was really not looking forward to that kind of job, dropping the gearbox seems like the only logical thing to do to have a proper assessment. Maybe I should look for a mech who can do a better job than I can for R500 max on labour

, doubt that one exist, otherwise, I'll book a weekend for myself to do it

Velofox · Post by **Velofox** » Mon Aug 01, 2011 5:36 pm

The pgti had dual mass flywheel. Need to replace the whole setup sadly. But rather do the tear down first

London · Post by **London** » Mon Aug 01, 2011 6:07 pm

Now that sound expensive as well, that flywheel goes for around R3000 if im not mistaken. Why wont I be able to use the one that I have if its still in good condition?

Spooln_4 · Post by **Spooln_4** » Mon Aug 01, 2011 7:24 pm

IMHO rather replace it with new one... Might save you from doing it again anytime soon...

Velofox · Post by **Velofox** » Mon Aug 01, 2011 7:46 pm

The pgti kit was R3.3k all parts Inc

London · Post by **London** » Tue Aug 02, 2011 9:01 am

PocketRocket wrote:IMHO rather replace it with new one... Might save you from doing it again anytime soon...

Thats true. Its then going to take some budgeting for that, maybe another month including this one, thats why I wanted to change the clutch kit without changing the flywheel. I'll just inspect it(flywheel) and see if it really needs replacing, otherwise, if its still good, im just going to use it again and hope for the best. Cant be without a car for more than 2 months.

joggiep · Post by **joggiep** » Tue Aug 02, 2011 12:24 pm

Might bw able to change it to a SM flywheel and pressureplate for cheaper....

Velofox · Post by **Velofox** » Tue Aug 02, 2011 12:26 pm

joggiep wrote:Might bw able to change it to a SM flywheel and pressureplate for cheaper....

Valeo is available at GW...

you will be able to transfer more to the wheels too

London · Post by **London** » Tue Aug 02, 2011 5:02 pm

In my research, they say single mass flywheel chutter alot, it makes noise at idle. Has anyone ever heard it and is it that bad?
BTW, my other option which I doubt that ill take, my friend wrote off his A3 2.0FSI Sportback, he said I can take his flywheel and the rest of his clutch components. His car was at about 120000km when he wrote it off.

I know that any other 6 speed VW/Audi gearbox uses internal slave cylinder, meaning its slave and throw out bearing are one thing, therefore no clutch fork. My gearbox is also 6 speed but it has external slave and uses clutch fork to actuate the release bearing. I think these gearboxes are only for 2.0FSI, im speaking under correction here. What are the posibilities that it might just be a bent/broken clutch fork? If it is, can I just get a new fork, put it in and continue driving or do you guys still think that its advisable to just change all friction materials?

Sinbad · Post by **Sinbad** » Tue Aug 02, 2011 5:22 pm

When i heard a car with single mass I thought the engine had bent a rod.

London · Post by **London** » Tue Aug 02, 2011 6:00 pm

Sinbad wrote:When i heard a car with single mass I thought the engine had bent a rod.

If thats the general noise they make, I wont be able to stand it, diesel cars are unbearable to me, im talking about old and unhealthy ones, just too much noise for my liking. I guess ill pass the idea of single mass flywheel.

London · Post by **London** » Mon Aug 08, 2011 9:59 pm

Finally had some time to take the gearbox out. Here's what greeted me as I was removing the pressure plate:

The culprit is a fatigued metal piece in red:

The results:

I guess new clutch kit is on the cards

!

London · Post by **London** » Thu Aug 11, 2011 7:06 pm

Okay I ended up taking the dirt cheapest route for two reasons.

1. It was very easy to remove the gearbox and I did it all alone by myself, for re-installation, I couldnt do it by myself so I asked someone for his 5 minutes to help me put back the gearbox. So all in all, its a job that I can do again anyday no problem!

2. I seriously need to save up because this thing hit me when I least expected it. I needed to get the car back on the road as soon as possible and i didnt have enough money for new kit. So im going to take couple of months to save up for a new flywheel and clutch kit.

Now the dirt cheap route im talking about here is that I ended up taking my friend's offer. I took his complete clutch kit and flywheel, his flywheel is still in very good condition, about no excessive play than a new one has. I only used his clutch kit and kept my flywheel intact as it was also in good condition. The car is now back and its driving beautifully. If and when this setup fails, I hope i'll already have saved enough to buy new kit. Thanks guys!