Firstly, I have viewed topics in this forum on many occasions, but now its my turn to post a problem. My car is an Octavia Elegance 60 plate. It is high mileage because of my work, but it is well maintained. At the end of August it passed its 6 monthly MOT with the need for an off side lower ball joint. I had reported to my mechanic a noise when I turned full left at the end of the road. A new ball joint was fitted. The change was immediately noticeable, and from then the car ran smoothly, both engine wise and suspension wise.

 

The following week, a noise developed when the clutch pedal was depressed from neutral to engage first gear, and similarly when changing from a gear to neutral. Normal driving no noise and everything still running smoothly, as in no vibrations.

I thought it was gearbox, and returned to the chap who had serviced the gearbox/clutch/flywheel two years earlier. He said flywheel, so the next day a new LUK clutch and flywheel.

 

This involved dropping the subframe, disconnecting driveshafts, gearbox and everything else underneath, as well as a lot of plastic in the engine bay to remove the battery.

 

Driving away from the workshop everything felt smooth and ok. Then it wasnt. I detected a vibration, which was diagnosed as flywheel, the mechanic took the car back and exchanged for a Sachs clutch and flywheel. He returned the car, having driven it the 20 miles or so home, I drove him home and the drive felt ok.

 

What is the puzzle is the vibration that developed, that felt like the wheels were juddering.

 

In between the two clutch/flywheel changes, I had the tracking checked at Kwikfit as I knew it would be out. The second flywheel he said he would put in without dropping the subframe.

I also had new tyres fitted to the fronts, and the nearly new tyres from the front put on the rear. These have since been taken off and I have reverted to the original tyre configuration for test purposes.

 

I am convinced the poor running of the car is a suspension issue, though when others have driven it, they dont feel what I feel. A gentleman from the local Skoda dealership drove it round the block and felt the clutch and flywheel was performing normally.

 

On several test runs, I have driven the car down a long hill, starting in high gear, putting the car in neutral, then switching off the engine and free wheeling down the long hill. The vibrations from the wheels remain throughout. To me that might conclude the flywheel is not the cause of the vibration.

 

So here is my dilemma:

 

1) A car just passed MOT is running smoothly after a ball joint is changed on the off side front.

2) A noise develops when depressing the clutch in neutral to either engage or disengage first gear

3) The mechanic who serviced the gearbox, change the clutch/flywheel 70+k miles ago reckons its the flywheel and the gearbox is good (actually crawling along in first it can jump out of gear)

4) The journeys in the car are still very smooth suspension and engine wise even though the flywheel has been diagnose as failing.

5) Clutch/flywheel exchanged

6) Vibrations

7) Tracking checked, new tyres front.

8) Sachs clutch/flywheel fitted

9) Rough ride, vibration through suspension, tyres changed back

10 Car can feel smoother when driving on very smooth tarmac (we actually do have that in Telford), but rough ride is exaggerated on normal/rough roads.

11) Seems to get worse as the day goes on..maybe heat, or maybe I just find it very tiring to drive.

12) symptoms apparent when free wheeling down hill with engine off. Obviously driveshafts and wheels are turning, but I have no idea how much of the gearbox is still in use.

13) Im not sure all the plastic under the bonnet is fitted 100% as when starting occasionally it can sound like a bit of blow on the first instance of starting, but I dont think that has anything to do with the main issue.

 

Car has gone from very smooth to very rough/bumpy/juddery

 

Im at a loss. I know how this car should feel to drive as I am in it every day doing at least 100 miles/day, and it isnt right.

 

Suggestions and pointers would be very welcome.

 

Thanks.

 

 

 

 

 

 

 

 

 

have the shock absorbers and springs been checked?

We have had the car up on the ramp at my own mechanics for a visual inspection.  We had replaced the drivers side lower ball joint after the MOT. What we noticed on the ramp was that the near side ball joint was for the drivers side, and was subsequently changed. As the MOT checked the springs and shocks were ok, and everything was smooth prior to the new clutch/flywheel being fitted, I have to assume they are still ok, unless of course dropping the subframe and disconnecting the driveshafts could have an effect. The mechanic who did the work is a gearbox specialist so again, I have to assume that the subframe and drive shafts went back in the correct position.

 

Im looking for something that could obviously affect the ride and cause vibration that is possibly as a result of dropping the subframe et al....

Has all the sub frame bolts been checked and do you know if they were replaced or reused as quite a lot of vw bolts are stretch bolts and should be only used once.

Shock absorber(s) would be my guess, but first check wheel balance. Check for play in track rod ends inner and outer and all bushes. Do rear as well as front. Check wheel bearings and  cv joints for smooth running (hand on spring while turning the wheel). 

Is the judder just under power? Worse going uphill? Drive shaft splines gearbox end?

He said its still there in neutral, coasting.

Thanks for the options..the vibrations is constant and worse on the rougher roads. Its there when I coast down hill with engine off. My starting point was everything was fine until the subframe and drive shafts were disturbed. All bolts were tightened up afterwards. Im hoping its something obvious but how can it be checked to see if everything is to specification.