I have been contributing to DSG flywheel discussions for the last few years, with my tale of rattling flywheel with no symptoms causing no problems. Well after nearly 3 years of flywheel rattling on my 2.0 PD DSG, it finally failed last week. I expected this to happen at some point, but what surprised me is the speed at which it got worse and the damage it did.

 

To recap, my flywheel started making a rattling noise when in P or N at around 60,000 miles. At first it only did this when the engine was cold, but then at some point (probably about 10,000 miles later) it would rattle all the time (still only in N or P....it stopped when in D or R). There were no other symptoms at all......until maybe 2 months ago (90,000 miles). I noticed that when idling there was a noticeable but very gentle shake that could be felt through the car when stopped.....in the back of my head I thought this could be the start of an engine mount failing, or maybe flywheel, but it wasn't my first thought and I wasn't overly concerned by it.

 

Then last week when my wife was driving it, she phoned me to say the car was vibrating badly and making quite bad noises (92,000 miles). I told her to drive it back gently and I would have a look when she got home. I knew at this point that the flywheel was probably the culprit. She got home and I heard it from inside the house.....it sounded awful. I went out later and attempted to start it where upon it make a loud metallic clang and started normally and was not making any bad noises any more. I knew at this point that the flywheel must have somehow got stuck off centre but reset when I restarted the engine (hence the clang noise!).

 

I had the flywheel replaced and here is the old flywheel:-     

 

 

 

As you can see the end of one of the springs broke....probably at around 90,000 miles. The new free play in the spring allowed it to contact the casing every time it was compressed. Eventually this caused the casing to get holed (2000 miles later) allowing the greese and bits of spring from the inside out into the bell housing. The bits of spring got momentarily stuck in the starter ring gear and put a few nice gouges in the bell housing. Luckily the escaped greese trapped the bits of spring in a little pocket of space near the starter motor. I was lucky.....a new flywheel and a bit of cleaning of the bell housing was all that was required. However if the flywheel had broken up any more it could have easily written off the transmission.

 

So if you have a DSG with a rattling flywheel and decide you really want to try to get maximum life out of the flywheel, be very aware of any changes....ie worsening of the rattle or any slight increase in vibration.....the flywheel is very near the end at this point. At no point did I get the classic vibration/judder at low RPM when accelerating.......the normal marker in a manual transmission with a worn flywheel.         

 

Good post. Thanx

i have light engine vibration when start on cold and light rattle noise wnen you load the engine on 4,5,6 gears. Is it the clutch coming to say good bye?

Good post. Thanx

i have light engine vibration when start on cold and light rattle noise wnen you load the engine on 4,5,6 gears. Is it the clutch coming to say good bye?

 

Unlike the manual transmission, on the DSG the clutches are inside the gearbox and do not interface with the flywheel at all. There is just a splined shaft coming out of the gearbox that connects with splined hole at the centre of the flywheel. 

 

Your flywheel sounds like it is pretty well worn. When you say vibration on cold start, does it do this just when it starts up or does it continue when the engine is idling?.....if so I'd get that flywheel replaced.  

It is just vibrates on cold start, rattling all the time but not getting worst I think. I suspect the clutch but not 100% sure.

if deside to take the gear box out what exactly I have to replace, whole assambley,clutch plate or flywheel?? Never had DSG before thats why so much confuse. Thank you

if deside to take the gear box out what exactly I have to replace, whole assambley,clutch plate or flywheel?? 

 

Flywheel only.....and 6 new flywheel bolts to be on the safe side.  

 

There is no clutch plate on the flywheel in a DSG.....it has wet clutches that are all inside the gearbox and rarely give trouble on the 6 speed DSG.....even at high mileage.  

Thank you for reply. Can I ask what sort of money it will cost

? I don't want to wait till it goes end, that little rattle make me mad so I have to take my wallet out asap.... :~( cheers

The flywheel is around £300 and new bolts around £10. Labour rates vary quite a lot but in my case cost £270.....so in total it cost me £580.  

Just got parts price from local Skoda dealer. Flywheel £653. Clutch £348 (they said the clutch itself may do rattle) + bolts, filter and oil. Labor I can do somehere else. In my case it is sound about 1300 pounds, not cheap.

Where did you order your parts?

Thank you

I got my parts from Euro car parts......you get the same part no matter where you buy it as LUK are the only company that make DSG flywheels.  

 

Did you tell them you have a DSG? It sounds like they have given you a flywheel and clutch for a manual gearbox......which will not fit a DSG. 

Of course I told, the pats man is my friend, i can even get about 15% discount from that amount but still dear a bit. I had the clutch kit to my manual Octavia from Eurocarparts if I remember it cost me lot less then from a dealer but the relise bearing start make a noise very quick so that think always keep me away dispite I know LUK only one who make a clutches. Thank you