My trusty 2004 Octy Mk1 estate has the 130BHP engine and 6 speed box. It has done 220,000 motorway miles with hardly a spanner on it apart from 2 cambelts and a steering rack. I have done 120k of that and previously it was a lease car with full Skoda SH. 

 

Recently it has been getting difficult to change gear, particularly 1st to second when cold but all the gears seem "baulky" and there is a rattling noise which goes away when the clutch gets depressed. It is still drivable but needs sorting as economically as possible as it is still a good car and I was hoping to get another year or so out of it before I replace it, (maybe with a new Scout  )

 

I presume this car has a dual mass flywheel. Is it likely to be this or the gearbox playing up? If it is the DMF should I convert it to SMF on hopefully a cost saving basis and what parts should I use? 

 

 

Sounds like flywheel to me, if I had to bet, as its the weak link.  The boxes themselves are real tough, so a much rarer failure.

Before assuming that it's box, flywheel, or clutch plate, I'd get the engine mounts, particularly console bushes and dogbone, checked, and check the linkage adjustment.

 

After that, my money would be on flywheel or worn driven plate, and they're both box out jobs.

Thanks

 

What are console bushes please??

I would also change the oil or at least check the gearbox oil level. The rattling probably is the release bearing or the dmf but unless its really bad it shouldn't affect gear-change. Also do a gear linkage alignment.

Thanks

 

What are console bushes please??

Front subframe to car. Oh and the dogbone is so called because if its shape.

 

Actually, yes check the gear oil level too. And at that mileage a gear oil change won't do any harm, but I'd eliminate needing to drop the box first for once, since you'd do the change then anyway.

It'll be interesting how you get on with this. I've had a sticky gear change for a bit now. No rattles or anything though. Changed the gear oil, alignment done, new linkage ends still no better. I was starting to suspect the clutch but its not slipping. Its even had new master/slave cylinders done a few years ago. Could it be the dogbone bush? Its still on the original one.

This has been diagnosed to almost certainly the dmf. Most cost effective solution??

Replace or convert to single mass flywheel?? If so with which bits please?? 

anyone??