S1 Gearbox & Transfer case - Metal found in the oil

[CB120]

Hey guys, im brand new to this forum.

Im coming here because unfortunately, ive found a lot of metal in my transfer case and gearbox. Something seems to be making a crunching sound while in reverse as well.

Ive stopped driving my car until i get a gearbox recondition & new transfer case.

Besides a direct replacement, are there any other gearboxes or transfer cases i can use on it? ive heard of people using golf R parts in their S1's.

If your gearbox has gone, let me know what happened and how you fixed it as well!

Info about my car :

2015 Audi S1 (based in australia)
70,xxxkm's
Was a stage 2 with an uprated intercooler, sachs clutch upgrade & resurfaced DMF, REVO Intake system and a 3" downpipe with 100cel cat

it is now stage 3 with an IS38 turbo, however i havent even driven it due to the discovery of the transfer case & gearbox oil situation.

Let me know!

Kind regards, Christian

 

[Newk]

Hi, if your still about did you get it sorted? Just having a new clutch done on mine and they have come back with a transfer box bearing gone which apparently requires specialist fitting.

 

[CB120]

Hi, if your still about did you get it sorted? Just having a new clutch done on mine and they have come back with a transfer box bearing gone which apparently requires specialist fitting.

hey mate, after 5 long months im finally getting my transfer case rebuilt.

I was also told a bearing has come out of my front output shaft inside my transfer case. Apparently its common on the 0A8 gearboxes / Transfer case / Front diff combinations. The metal softens over time and it comes out. Let me know what they told you

I was getting mad gear crunching sounds when my haldex would engage (it was from the inside the transfer case making the noise). Im happy to also send a photo of the oil to compare with yours if you want


my advice would be dont drive the car. the more you drive it, the more damage you do.
Your options are :
A.) with audi, they will fit a new transfer case for you. In australia they quoted me like $9000aud for the part (not the labour).
B.) get the transfer case re-conditioned. This is what im doing, and its costing me $4200 aud. I should get my car back by monday so ill let you know the go, but please take your choices carefully and dont drive !

 

[Newk]

I wasn't getting any issues with it, it was only cause the clutch has started slipping after a stage 1 that they found it while fitting new clutch. Just had words with the guys doing it, apparently pulled a favour and managed to have the transfer box refitted, and upgraded bearings at the same time. Bearing in mind they already had it stripped out and whole job quoted for they are charging me £280 extra for the box refurb.

Having a paddle clutch fitted, which is apparently 480 ft/lb rated, so good to go to stage 3 if I want, then see what breaks

 

[CB120]

I wasn't getting any issues with it, it was only cause the clutch has started slipping after a stage 1 that they found it while fitting new clutch. Just had words with the guys doing it, apparently pulled a favour and managed to have the transfer box refitted, and upgraded bearings at the same time. Bearing in mind they already had it stripped out and whole job quoted for they are charging me £280 extra for the box refurb.

Having a paddle clutch fitted, which is apparently 480 ft/lb rated, so good to go to stage 3 if I want, then see what breaks

That is very cheap for a box refurb... get an invoice of all the parts man, thats suss. Unless im getting ripped off, which is a possibility!

 

[Newk]

That is very cheap for a box refurb... get an invoice of all the parts man, thats suss. Unless im getting ripped off, which is a possibility!

I unfortunately think you were right, after 500 miles bedding in the NEW paddle clutch is not holding, even in eco mode. Possible Audi refit required and legal battle to ensue. This maybe an awkward one as they will inevitably say it wasn't bedded in properly. Also charged for a new DMF saying the old one was 'burnt' despite putting it in eco mode and taking it easy as soon as any problem became apparent. They are not replying to my phone calls nor emails.

Anyone know a legal geagle in the UK who can assist?