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Hi and sorry about the dodgy title but I though it would get extra attention and I need help urgently. Also I mean the title literally.
I'm having clutch/flywheel problems with my 2007 8P S3 and my mechanic can't find anything wrong. I just had a new clutch, dual mass flywheel and release bearing installed and now I have these problems...
1. Droning noise when I decelerate through 2500rpm.
2. Occasional rattling noise from the gearbox when I let the clutch out.
3. Occasional knocking noise at idle and in neutral.
4. Clutch pedal shakes/judders and gear lever too.
5. Occasional power loss/surge.
6. Stiff gear changes in all gears and sometimes won't go in at all.
Anyway, back to my shaft...
I got my mechanic to take the gearbox out again because I said I wasn't happy. I was hoping to see something obviously wrong but there wasn't, except maybe... my input/clutch shaft splines.
Do the splines on the end of the input shaft have little ridges? It's like they are serrated all along the tops of the splines. Also I thought I could feel a slight mushrooming on the splines. The last 10mm of the shaft felt wider than the rest of the shaft. The other thing I noticed is that it had no grease on it, bone dry. Also there were streaks of grease coming out of the middle of the clutch hub/centre. Sorry I don't know the right words for the parts but I hope I'm making sense.
Is it possible there was no grease or too little grease or the wrong grease on the shaft?
Any help here would be greatly appreciated.
Hi,
Joking aside,the first thing I'd say is that if all this has started since replacing the clutch and DMF,then that's the cause of the problem,and it's the mechanic's job to sort that out.
All of the problems there would fit with the clutch plate not moving correctly on the splines,and if,as you say,the splines are ridged and mushroomed,then they sound either worn or damaged.
If you google gearbox shaft splines,you'll get a very good impression of what they should look like.....elongated teeth as on a gear but longer,and smooth down their sides and top.
They should not be ridged,scarred or obviously worn.
If the shaft is completely free of grease,that may also lead to the clutch plate sticking.
I can understand a little bit of grease from the centre of the clutch bearing,as long as this hasn't got onto the clutch plate itself,as this would also knacker it,but it would slip rather than judder.
Was this done at an Audi dealership?....if so,drive it up there,park it and complain loudly in the showroom until it gets sorted....failing that,a phone call to VAG customer services may also concentrate a few minds.
I appreciate that the most likely cry will be one of wear and tear,but a splined shaft is not expensive,and is pretty easy for them to replace,but the point is they should have noticed,and informed you,rather than giving you back a car that doesn't quite work.
This picture isn't great,but it does show the shaft I think you're talking about,running into the box,and it isn't ridged or damaged.