2.0 TDi Sportback eating dogbone mounts?

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revilo

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Had anyone ever heard of a car to eat through dogbone mounts?
I had mine replaced 3 weeks back and this weekend it began knocking in exactly the same way it was 3 weeks ago..

I have had trouble with various engine mounts in my car, could this all be related?
Contacting my garage tomorrow to get it checked but I'm possibly looking at a few weeks wait!

Any ideas?!
 
Would it be best to look at replacing all the mounts?
 
Alright Ash! :)
Can you link me to the THS ones for my car? Already got the insert :)
 
Perfect, i'll have a gander at them!

I have the ECS Tuning Insert.
 
oh k i dont know how that performs, i have heard loads of good things about the powerflex ones and i personally have one with no faults
 
Do you get more engine vibration with powerflex mounts? Are there any downsides?
 
the only difference i've noticed is when i put my foot down.. it feels like there's more pull and sooner...
 
After a chat with my mechanic yesterday, he thinks the issue comes down to 2 things; the lower engine mounting bolt had to be re-helicoiled due to a failure, this is probably still weak!
and secondly, the amount of strain that is being put on the mount is higher due to tuning.

Solution; we are designing and making a custom mounting, this will complement the dogbone mount and provide extra strength..

Will update with results!
 
Strange, if helicoiled properly its usually stronger than the original fixing or at worst as good as the original. As for designing your own mount, nice idea, but as the dog bone design is identical across all the various models the subframe mount is the only weak point (again same part used) which can be more than successfully bolstered to take whatever abuse you could throw at it by using a £20 insert.
 
That's exactly my thoughts regarding the helicoil, my mech mentioned that the last one looked like a bad job, and I trust him to have repaired that correctly..

I am already using the ECS tuning insert, but when installing this, it seems to have had these issues more regular? That may be coincidence though..

If the helicoil has gone again, I am stuck with 2 options:
  1. Go up another size on the helicoil
  2. Redesign the mounting for a custom design..
Do you have any more suggestions to try?? This is becoming a massive headache, and the knock has become pretty violent over the weekend...
 
If you've still got knocking when the insert is in check the bolt which mounts to the bottom of the gearbox, if this is ok & the knocking still persists more than likely your NS (top) mount is knackered.
 
max69vk said:
If you've still got knocking when the insert is in check the bolt which mounts to the bottom of the gearbox, if this is ok & the knocking still persists more than likely your NS (top) mount is knackered.
Click to expand...

The bolt which mounts to the gearbox is the one which was helicoiled, so in theory should be pretty sound..
Is there an easy way to check if the top mount is the culprit?
 
audi upgrades
If that's the one that's coiled check the rear bolt that goes through the subframe mount. Again, if its ok it points towards the problem being the NS gearbox (top) mount.
 
To check it you can put the car in 1st gear with the handbrake on & slowly let out the clutch to see how much the engine moves.
 
max69vk said:
If that's the one that's coiled check the rear bolt that goes through the subframe mount. Again, if its ok it points towards the problem being the NS gearbox (top) mount.
Click to expand...

The rear bolt would be the one with the insert?
Where can i find the NS gearbox mount?
 
Top of the gearbox under the battery, just give the engine a pull/push from the top by hand & you'll soon know if its got problems, just listen for any knocks or bangs & look for excessive movement.
 
max69vk said:
Top of the gearbox under the battery, just give the engine a pull/push from the top by hand & you'll soon know if its got problems, just listen for any knocks or bangs & look for excessive movement.
Click to expand...

Just tried to give it a shake, nothing unreasonable from the movement side and no noises.

A couple of things I noticed on the drive home from work:
  • The gears sometimes snag when moving the gearstick and moving from first to reverse requires me to pump the clutch a few times.
  • When turning the engine off, the knocking sounds almost like something rumbling/rattling a couple of times..
 
The rattle when turning the engine off could be DMF.
 
If this helps, here is a list of symptoms:

  • When starting the engine I get 1 or 2 knocks
  • When changing direction (forward to reverse or R to F) I get on loud knock
  • When changing between 1st and reverse I sometimes have to pump the clutch a few times
  • When changing up gears when pulling away sometimes I hear/feel a few knocks
  • When turning the engine off I get either a loud knock, or a few rumble type knocks
Related work so far to solve this:

  • Replaced Clutch and DMF
  • Minor adjustment required to lcutch due to rubbing on DMF
  • Gearbox mounting bolt sheered, re-helicoiled
  • Poly insert installed into subframe mount
  • Dogbone ruined due to engine play, replaced
 
recommend THS mounts with powerflex lower engine mounts
easy to change aswell
 
Jord said:
recommend THS mounts with powerflex lower engine mounts
easy to change aswell
Click to expand...

I'm definitely going to get a new set of mounts after this, however, after doing some trawling online I think the issue is with the DMF.
Mainly because when i turn the engine off/on, i can hear and feel a rattle/rumble, not a loud knock anymore..

Has anyone had DMF issues like this before?
 
revilo said:
I'm definitely going to get a new set of mounts after this, however, after doing some trawling online I think the issue is with the DMF.
Mainly because when i turn the engine off/on, i can hear and feel a rattle/rumble, not a loud knock anymore..

Has anyone had DMF issues like this before?
Click to expand...

My DMF rattles a bit when turning the engine off. It stops when I press the clutch pedal. It has been doing it for two years now.
 
SAiLO said:
My DMF rattles a bit when turning the engine off. It stops when I press the clutch pedal. It has been doing it for two years now.
Click to expand...

I would say this isn't the kind of rattle i would ignore, it's audible from the outside and i can feel it in the clutch pedal..
Pressing the clutch in when turning the engine off doesn't help it seems...
 
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