Hi everyone and anyone who may be able to help, so a few weeks ago on my way to work i lost all gears but to cut a long story short we replaced a previous eBay special flywheel & clutch kit with an LUK one... finally got everything back together after the nightmare of figuring out that issue but now it just wont start, when i try to turn it over the starter motor makes a click and if i try a couple times, same problem but it gets hot quickly, starter motor isnt seized either, it did sit for roughly 3 weeks but battery and starter motor were in the boot, any suggestions? Would be greatly appreciated

Starter gear jammed on ring gear?

But best test or charge the battery even though it has been 3 weeks in the boot. 

5 hours ago, MicMac said:

Starter gear jammed on ring gear?

Im not very familiar with this stuff so if you mean is the starter motor seized, no it still moves but even disconnected with jump leads attached to it, there is no movement from power. If that was what you meant then i hope i answered the question.

5 hours ago, roottoot said:

But best test or charge the battery even though it has been 3 weeks in the boot. 

Yes it has been taken back off now and my brother is taking it to work to charge it for the day, he believes its the starter motor but i did read up a little before posting my initial post and i did mention the battery so hopefully it is just that and it will hopefully be ready to go tomorrow

1. How do you know the starter motor is free to move under power?

 

2. Pertaining to the nightmare clutch job, I alluded the starter/clutch assembly being incorrectly fitted and binding.

10 hours ago, MicMac said:

1. How do you know the starter motor is free to move under power?

 

2. Pertaining to the nightmare clutch job, I alluded the starter/clutch assembly being incorrectly fitted and binding.

Oh i see, yeah the starter motor moved by hand but not with power when hooked up to jump leads.

 

And i have no idea, im not mechanically minded but my brother is a mechanic but not overly familiar with VAG cars so i dont know

10 hours ago, MicMac said:

1. How do you know the starter motor is free to move under power?

 

2. Pertaining to the nightmare clutch job, I alluded the starter/clutch assembly being incorrectly fitted and binding.

My brother says the clutch is definitely fitted correctly, he is charging the battery all day today at work but has said he believes its the solenoid (if im spelling that right) in the starter motor, probably another eBay special like the Clutch & SM Flywheel kit, so battery will be tested tonight and if thats not helped then it must be the starter motor now

16 hours ago, Pegg said:

finally got everything back together after the nightmare of figuring out that issue but now it just wont start, when i try to turn it over the starter motor makes a click and if i try a couple times, same problem but it gets hot quickly,

A starter motor will not fail from being removed and refitted, that it gets hot when jammed shows that the full current is flowing, your brother is likely not testing it correctly with jump leads, does it get hot when it clicks now?

 

It is possible that you burnt it out by engaging it while jammed.

 

I have used the word "jammed" twice, the only thing that has changed is the flywheel and its ring gear, I suspect they are incorrect or incompatible with your starter motor pinion, that is where your brother should look before buying a new starter that may not be needed and possibly burning that out as well.

17 hours ago, Pegg said:

finally got everything back together after the nightmare of figuring out that issue but now it just wont start, when i try to turn it over the starter motor makes a click and if i try a couple times, same problem but it gets hot quickly,

A starter motor will not fail from being removed and refitted, that it gets hot when jammed shows that the full current is flowing, your brother is likely not testing it correctly with jump leads, does it get hot when it clicks now?

 

It is possible that you burnt it out by engaging it while jammed.

 

I have used the word "jammed" twice, the only thing that has changed is the flywheel and its ring gear, I suspect they are incorrect or incompatible with your starter motor pinion, that is where your brother should look before buying a new starter that may not be needed and possibly burning that out as well.

 

Frankly a mechanic should not need that advice and should automatically suspect a problem with or incompatibility of the new part fitted.

5 hours ago, J.R. said:

A starter motor will not fail from being removed and refitted, that it gets hot when jammed shows that the full current is flowing, your brother is likely not testing it correctly with jump leads, does it get hot when it clicks now?

 

It is possible that you burnt it out by engaging it while jammed.

 

I have used the word "jammed" twice, the only thing that has changed is the flywheel and its ring gear, I suspect they are incorrect or incompatible with your starter motor pinion, that is where your brother should look before buying a new starter that may not be needed and possibly burning that out as well.

 

Frankly a mechanic should not need that advice and should automatically suspect a problem with or incompatibility of the new part fitted.

Yeah i should have clarified the starter motor gear moves by hand but not with power, it does click when it gets hot, i think we may have burnt out a cheap one that isnt compatible with proper parts, the starter motor fit and ran the SM flywheel before the clutch broke, but no luck now, my brother also said the starter motor was acting up last time before we fit these LUK parts, so will test the battery first tonight and if there is no improvement then we'll have to try a new starter motor, like i say hes adament its the starter motor and is picking one up today so fingers crossed my car will be raring to go tonight

On 15/08/2022 at 10:48, J.R. said:

A starter motor will not fail from being removed and refitted, that it gets hot when jammed shows that the full current is flowing, your brother is likely not testing it correctly with jump leads, does it get hot when it clicks now?

 

It is possible that you burnt it out by engaging it while jammed.

 

I have used the word "jammed" twice, the only thing that has changed is the flywheel and its ring gear, I suspect they are incorrect or incompatible with your starter motor pinion, that is where your brother should look before buying a new starter that may not be needed and possibly burning that out as well.

 

Frankly a mechanic should not need that advice and should automatically suspect a problem with or incompatibility of the new part fitted.

Yeah im losing my patience now as this has taken forever and this should have been done by now... i have nearly no mechanical knowledge, i can do a service and have changed some exhaust systems on motorbikes but thats it... can you or anyone else please tell me if what im thinking is correct... so the flywheel bolts from the eBay SMF kit didnt match the LUK DMF so my thinking is that the clutch face bolts wont match either, they were fitted and pressed against the flywheel pushing the clutch away from the flywheel, i believe this jammed the clutch against the inside of the gearbox casing which also stopped the flywheel stopping the engine from starting... thats my theory but my brother wants to check and make sure the clutch is correct but everything seems to line up... so am i correct in my assumption and in need of shorted bolts for the clutch plate? Because im at the point of wanting to cut the bolts we do have down to what i believe is the correct size where they wouldnt be causing a jam because at this point im losing confidence in my brother

Unlikely, try simply rotating the engine by hand, better still push start it.

30 minutes ago, J.R. said:

Unlikely, try simply rotating the engine by hand, better still push start it.

Its a diesel so push starting is difficult as far as im aware, also the bolts were definitely touching the flywheel and there was definitely some contact with the gearbox casing and the clutch face plate because there is a marking inside the casing and also the outer casing cracked when being taken off again due to the pressure build up, have also tried to rotate the flywheel before gearbox was taken off and it wouldnt move, but moves without gearbox on

Well it would have saved a lot of time had you said that in the first place instead of talking about starter motor failures, if the flywheel would not turn before you removed the gearbox then the car was not running, surely the first thing to do after replacing it would be to make sure it wasn't still jammed as soon as the first 2 bellhousing bolts were cinched up.

 

Your brother has re-assembled everything and now he has t take it all apart.

 

The clutch cover bolts are supposed to touch the flywheel, they screw into it.

 

You have incorrect or incompatible parts fitted, was the LUK set a complete clutch/DMF kit?

 

Is the gearbox the original one or the correct type for the vehicle VIN number?

Well it would have saved a lot of time had you said that in the first place instead of talking about starter motor failures, if the flywheel would not turn before you removed the gearbox then the car was not running, surely the first thing to do after replacing it would be to make sure it wasn't still jammed as soon as the first 2 bellhousing bolts were cinched up.

 

Your brother has re-assembled everything and now he has t take it all apart.

 

The clutch cover bolts are supposed to touch the flywheel, they screw into it.

 

You have incorrect or incompatible parts fitted, was the LUK set a complete clutch/DMF kit?

 

Is the gearbox the original one or the correct type for the vehicle VIN number?

 

And if the starter motor really will not turn when actioned with jump leads and your brother actually knows how to connect it to test then you have burnt it out trying to turn over a locked up engine.

 

You say the car is a diesel yet your profile shows it as a 1.2 TSI petrol, have you ordered parts for the correct engine?

 

The diesels will push start relatively easily in a higher gear but not with a locked up engine.