For a while now I have noticed a resonance from the engine bay at 1,500 rpm, especially when crawling in 1st gear. A couple of mornings the engine has sounds a bit noisy at startup, from outside the car. This morning it was noticeably noisy, sounding like a leak around the manifold area. It sounds fine when driving. Called our dealer who seemed reluctant to believe it was an exhaust noise and to call out Škoda Assist. Planning to do that when we get home, but is there anything common in this area? Cracked manifold? Blown gasket/joint? The car is 32 months old, around 38,000 miles. I assume if it is simply an exhaust fault the warranty won't cover it?

Edited 27 September, 201411 yr by weasley

If it involves any exhaust leaks it's effectively an emissions fault which makes it technically unroadworthy and should be covered under warranty.

I seem to recall pollution related components have a min ten year design life also.

I'm sure that, unless you have hit it on a rock or something, your exhaust will be covered under the three year warranty.

So, the Skoda Assist man tentatively diagnosed the DM flywheel. This would fit with a recent musing I made to my wife that "the clutch feels a bit heavier than usual". Need to get it into the dealer.

Off the car went to the dealers with the expectation it'll be back today.  Given that the dealer only had speculation to work with I was surprised they suggested a return date.  Anyway, the call came today (taken by the wife, so this is second-hand):

 

 

the clutch plate has fallen apart and has damaged the gearbox housing.  They are trying to contact Skoda UK to see how to proceed, but they are at an all-day training event today.  They will have to either replace the housing or the whole gearbox but are awaiting instruction from Skoda before they can order parts.  The car will probably be ready mid-to-late next week."

 

 

This will be why the clutch felt a bit odd then.  Although, given that explanation, I am surprised it worked at all!  There was no indication of clutch problems from how it engaged (no shudder or slip), just an oddly heavy pedal.

So, the verdict is in.  The car came back today.  I spoke to the servicing dept who said that a finger (from the clutch pressure plate) had broken and fallen into the gearbox housing, damaging it (I assume this would be the bell housing).  I have a new gearbox and clutch.

 

How this car ran with little more than a light noise is beyond me.  Other than the noise and a slightly-heavier-than-usual-if-you-really-knew-to-feel-for-it clutch pedal, you'd never have known anything was wrong with it.

 

Whether or not this has anything to do with the 1,500 rpm resonance remains to be seen/heard/felt.

Edited 9 October, 201411 yr by weasley

Hmm is your vehicle a 6 speed manual gearbox ?

As Weasley's details show he has a 140 SE, then yes it is a 6 speed.

Yes, a 6 speed manual. And the wife now reports a 'whine' at 50 mph. Investigations will continue...

So, I have diagnosed the "whine".  It is the roofbars whistling!  The car drives fine - the gearbox feels new but is essentially exactly like the old one.  The clutch biting point is a bit lower but is light and progressive.  The dealer called today to get the car back to perform "a software update for the gearbox", which is good because while they have it thet can also straighten the steering wheel, which was straight before the work was done!

Sorry. " a software update" for a manual gearbox, they're havin a laugh.

How this car ran with little more than a light noise is beyond me.  Other than the noise and a slightly-heavier-than-usual-if-you-really-knew-to-feel-for-it clutch pedal, you'd never have known anything was wrong with it.

The finger will have dropped down to the bottom of the bell housing and would have been just rattling about down there.  The damage it caused on the way down may have just been superficial or possible just chipped some teeth/cogs/etc on the way through.  So, enough to cause resonance/noise but not enough to affect the function of the gearbox.  Of course, it it had moved again or bounced aroud it could have eventually done more damage or jammed something up.

 

Cheers

 

Rog

Sorry. " a software update" for a manual gearbox, they're havin a laugh.

There will be a gearbox ECU...

 

Cheers

 

Rog

There will be a gearbox ECU...

 

Cheers

 

Rog

And what exactly does a manual gearbox ECU do ?

And what exactly does a manual gearbox ECU do ?

It tells/advises you when to change gear.

 

Fred

The software update might be for the engine ECU, in connection to the gearboxes parameters...?