TLee

Hi all, Have just found a leak coming from the heater houses that go from the engine to the cabin heater through the bulkhead firewall. At first it looks very difficult to replace but in reality if you follow the steps below the process is rather easy and took just over an hour. Only one pipe was leaking (split) but replaced both just in case. The part numbers for the pipes are 6R0-122-073-1-A and 6RO-122-157-L. The parts diagram is somewhat obscure and it was a bit difficult getting the right part numbers. One end of each pipe has quick connect couplings, but i removed them, as the quick connect on the bulk head didn't want to budge. The whole process is in the attached images done in the order of the images from 1 to 7

Hi All, Have the box out and have found the cause. Locking pin (18) in the parts image attached had given way, causing the short shaft (9) to slide through the spider gears (10) and that shaft then makes contact with the inside casing. As soon as it starts removing case material and structural ribs from the inside of the diff housing (24), that material builds up, jamming between the case and the end of the shaft, causing more damage, until the case cracks open. The shaft (9) eventually fails, cracks and becomes even looser to the point if the vehicle keeps driving it can lock up. Somewhat of a safety hazard. It also caused case damage in the clutch bell housing casing , (see image) allowing oil to get on the clutch face and wreck that too. So new refurbished complete gearbox and clutch for around €1350. Apparently the figure is around 3% with the KFK boxes in Volkswagen Auto Group VAG vehicles over 7 years old, and is a design flaw on the part of VAG that is not of great concern due to the vehicles being out of warranty. Its common, but low in numbers in reality compared the number of vehicles using this box on the road.

Thanks all for your replies. (nige8021 and Murdockman, I am expecting it to be something like what you have stated.) Will be getting it out hopefully this week and will post the outcome here

I have a 2011 Skoda Fabia 1.6l TDI Diesel with a 5 speed manual box that has just cracked open the differential casing.Occurred entering onto a main freway under acceleration. Loud thud, puff of smoke , thought I had ran over something.Pulled over and inspected the vehicle, saw oil spray in the engine bay. Strong smell of gear oil. Assumed it was possibly a drive shaft seal. Vehicle still drives, no whine or noise, slight clutch shudder from 1st gear possibly due to oil on the surface of the clutch. Carefully and slowly got the vehicle back home, and removed the underbody tray to find the issue attached in the photos. What do you think may have caused this, or is this something common with KFK version gearboxes?