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Stage 3 dxd clutch, juddering and missing gears

Discussion in 'Audi S4/A4/A4 Cab (B7 Chassis)' started by Craig Cull, Oct 24, 2013.

  1. Craig Cull
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    Craig Cull Well-Known Member

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    [Oct 24, 2013]
    Hi guys, as some of you may know, ive been spending alot on the k04 hybrid conversion. I went to APR and bought a stage 3 endurance clutch with a single mass fly wheel. Otherwise known as the dxd stage 3 kit. After bedding in gently and doing exactly what i was told, im having problems...

    Its juddered if you set of gently after about 600 miles, (stupidly) i thought this was the nature of the clutch. When giving it some, i go to change geat and it crunches like ive not even pressed the clutch pedal. Fine when driving normally, just notchy when changing gear. Once again i just thought it was down to the nature of the clutch. APR. Have told me to have it pressure bled and to see how it goes. So earlier i took it to my mechanic who got in the car to drive onto the ramp to bleed it and he said "its juddering its bollacks off"! You have a warped clutch disc! Or flywheel or both. It did come all the way from tue states and its a good chance it could have been launched off the 747 it arrived on. APR want me to dismantle it and take pictures..... Sounds cheap APR.... But how would you see a warped disc by a photo???? There happy to help but this is slowly becoming a ballache. Especially for £1000 when the wife could have put me through the same pain for free! Any suggestions or am i in for a rough ride?
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  3. adamss24
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    adamss24 Well-Known Member

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    [Oct 24, 2013]
    Unfortunately that's the nature of uprated clutches, i had 2 so far: a southbend clutch stage 3 OFE with a TTV Racing single mass flywheel and a Sachs SRE uprated clutch with standard DMF. Both juddered on take off but at least the DMF is smooth on idle... I can assure you that i bed in the clutches properly driving like miss daisy for the first 500-600 miles...
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  4. Craig Cull
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    Craig Cull Well-Known Member

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    [Oct 26, 2013]
    the juddering in can live with but the crunching into gears is really pissing me off. Had a nice fast drive yesterday on the back roads on my way out to see my mum and dad.... Missed 3rd gear every time, unless I double de clutch. For £1000 it's no good. in APR's defence they are sending me a full clutch and have been most helpfull. I'm just annoyed that I went the right way and put a decent clutch in and it's having my pants down.
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  5. adamss24
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    adamss24 Well-Known Member

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    [Oct 26, 2013]
    I would check the fork is not bent when you remove the gearbox and i do hope the release bearing is the right one on yours. On mine the release bearing had a alloy sleeve to increase the throw, i know some companies are supplying their SMF and clutches with longer push rod for the slave cylinder- maybe that's the issues with yours. Crunching is not good for the sincro's so i will check everything before taking the box off...
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  6. Craig Cull
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    Craig Cull Well-Known Member

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    [Oct 26, 2013]
    Ok mate, thanks for the advise, to be honest, its got worse as it bedded in. Eg, let the hand brake off, de clutch and select 1st gear and the car jumps like its not disengaged. Ill ring them and make sure theyve sent the correct release bearing. Maybe this the main issue? Hope i havent shafted the gear box....
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  7. sewell10
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    sewell10 Member

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    [Oct 26, 2013]
    Duel mass flywheels are fitted for a reason
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  8. Craig Cull
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    Craig Cull Well-Known Member

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    [Oct 27, 2013]
    I thought it was just to make everything smooth? The singlemass really turned it into a way more responsive animal, not mention the fact it rev's up so much quicker.
    If i thought for one minute that the results would be so serious, i would have probably left it alone.
    But im definatly going to exceed the torque ratings of the original dual mass, so i thought i didnt really have an option tbh?
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  9. Craig Cull
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    Craig Cull Well-Known Member

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    [Nov 8, 2013]
    APR have kindly supplied me a new clutch and flywheel to fit, as the kit isnt suppose to suffer from the symptoms that i have been dealing with. To be fair to them, they have looked after me in every way possible and are determined to find a solution. So fingers crossed!
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  10. adamss24
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    adamss24 Well-Known Member

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    [Nov 9, 2013]
    Let us know what you find when you swap the clutch...
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  11. Craig Cull
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    Craig Cull Well-Known Member

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    [Nov 9, 2013]
    Well... Full clutch and flywheel installed today and its spot on! Drives like oem and changes perfect. No juddering what so ever!
    It appears the flywheel is warped, you can see where the clutch disc has been catching the flywheel causing it to get that hot it has a blue spot... Along with the pressure plate. Also the kevlar has glazed on the disc where it has been catching. Looks like it must have been dropped off the boeing 747 it arrived on. Also no vibration whilst driving and a much quieter gearbox.

    So, ill report back in 500 miles once bedded in and ill let you know the final result. So far so good :)
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  12. ruairi83
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    ruairi83 Active Member

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    [Nov 9, 2013]
    Good to here mate.
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  13. Craig Cull
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    Craig Cull Well-Known Member

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    [Nov 22, 2013]
    Hi guys, just reporting back now the bedding in is complete.... All I can say is, totally different car. Feels OEM and drives like you wouldn't believe!! No juddering whatsoever and changes gear swiftly and positively!! Highly recommended!! Thanks APR UK for looking after me and seeing my warranty claim through quickly and painlessly. :) thanks for all your input guys aswell.
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  14. Keane
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    Keane Active Member

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    [Nov 22, 2013]
    Awesome customer service :) good job
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