Transmission Damage? Getriebe Reparatur.

Hello fellow mechanics.

After my car had been damage-free for a long time, I managed to cause some damage again tonight.

The following problem:
I was exiting a roundabout, slightly angled in third gear, I pressed the accelerator, the car lurched, and suddenly the RPMs shot up, but I had no more acceleration.

If I'm stopped with the engine running, and I press the clutch and put it in gear, everything is normal. But only when I release the clutch now, there's a loud rattling sound and nothing happens. The car stays still . This happens in every gear.

What could that be? A differential? Could the driveshaft be rotated? Is there some kind of gear involved? Could it be that the gear on the crankshaft, where the clutch is located, is damaged? That would be quite bad.

Here are a few more details. The engine is an AFN, the transmission is from a 1Z (220,000 km), the clutch with dual-mass flywheel is also from an AFN (22,000 km). The drive shafts are also from a 1Z (220,000 km). The engine has a chip tune, and it's tuned for the 90 horsepower transmission.


PS: The database didn't return any relevant results. Only 'donalexo' had something related to the A3, but it wasn't discussed.

Before I examine the inside of the transmission, a quick look inside the transmission bellhousing should be helpful.

You can see if the crankshaft timing gear is still intact, whether the clutch might have disintegrated, etc.

Perhaps even just a glimpse through the observation hole in the bell (if you can already see something small through it...) would be enough.

What happens when the car is moving and you are engaged or disengaged? This is essentially the opposite test to "engine running, car stationary," because in this case, the parts that are stationary in the first test are moving, and vice versa.

m;

Hi,
First, as I mentioned, I would check the clutch.

Look HERE and HERE.

Maybe it's 'just' that...

CU Gremlin.

I just started taking out the transmission. It's a lot of fun working on a Golf 3. Especially the transmission mount. Great! And almost all the screws on the driveshaft were stripped. I had to weld on new screws everywhere. It's been a lot of fun so far.

I touched the friction disc and it's true, the splines are stripped. Just like in the photos from Gremlin.
How can that be?
However, it was not an original VW clutch.

I once felt the serrations on the friction disc, and it's true that the teeth are actually sheared off, just like in the photos from Gremlin.
How can that be?

Force x Lever Arm = Torque

And almost all the screws on the drive shaft were turned around.
How did you manage that?

1. verschandeln thoroughly.
2. Attach a high-quality tool.
3. screw it on.
It has been working perfectly for 10 years .


I touched the friction disc and I can confirm that the teeth are indeed damaged, just like in the photos from Gremlin.
How can that be?
However, it was not an original VW clutch.

theory: the ZMS (clutch master cylinder) is defective. The torsional damper is integrated into the flywheel and realized via a kind of planetary gear between the flywheel and the pressure plate. Springs are then used for the actual damping, which resist the twisting force (similar to a conventional pressure plate). However, the gear mechanism can seize and jam, causing the damping to decrease, and the hard impacts to be fully transmitted to the teeth...

Ah... found the image:
http://www.sachs.de/owx_medien/media86/8676.jpg


Okay, so tuning is not an option? Although, the TDI in the pictures hasn't been tuned either, and it's only used for typical everyday driving.

Sure, here is the translation of the text from German to English:

'Cu Gremlin'

Golfmann wrote the following:
And almost all the screws on the driveshaft were turned loose.

How did you manage that?

I used to be a world champion at that.
Hab immer so ein Pech. Das Werkzeug ist gut. Ich hab nur gutes Werkzeug. Really?

So Gremlin: What's your theory suggestion?

ZMS sauber machen. Or new?

According to your theory, that would mean that a normal clutch would constantly break down, right? Or have I misunderstood something?

Werde mir das morgen mal genauer anschauen. War eben zu dunkel. And it's too cold.
Then maybe we can have a more in-depth discussion about it, using some photos of me.

Cleaning is a hassle, so I just hammered the nut in and then tightened the bolt. It's been quiet ever since.

According to your theory, that would mean that with a normal clutch, it would constantly break down?! Or have I misunderstood something?


In a normal clutch, the torsional damper is located in the clutch disc. Can you remember the discs with the springs inside?

CU Gremlin.

@ Gremlin

Do you remember how that happened with the golf club in the photo?

War heute bei VW und bei dem, wo ich die Zubehörkupplung gekauft habe. Die haben sowas noch nie gesehen. Nur sagt der aus dem Zubehör mir, das man nicht die Sachs Scheibe auf der Luk Kupplung fahren soll, oder andersrum. NAbsolutely!
Could there be differences in precision or fit?

I really have no idea how something like that could happen. If it's properly installed, there shouldn't be anything left that could wear out!

Has anyone else ever seen something like this, and could perhaps offer me some advice?

Could there be differences in precision or fit?


No, the friction coefficients are matched. LUK uses lower friction coefficients in the clutch linings and compensates for this with a slightly softer pressure plate. Sachs uses slightly thicker linings that contain a softer compound.

Hello everyone.

My car is back in working order now. It was exactly what Gremlin had in the photos. The teeth on the clutch disc were worn down!

My car has been running again for almost 1000 kilometers now.

I'm currently having the following problem (in my head ).
Will it last this time? What was the cause? A complex interlocking mechanism doesn't come apart so easily. And that rocket isn't exactly what my car is either.

@Gremlin, what repairs were done on the car in your photo? Was it just the windshield? (Like mine!) Did it hold up?

@Gremlin, what was repaired on the car in your photo? Just the windshield? (Like mine!) Did it hold up?

Good question...

I had to wait a few days until everyone was back from vacation.

CU Gremlin.

Did you apply MoS2 grease to the crankshaft splines when assembling the clutch?

I learned about this as an "absolute must-have." Back then, they said, "Otherwise, you'll have to take it all apart again very soon."

m;

Did you already apply MoS2 grease to the crankshaft splines when assembling the clutch ???

I learned about it as an 'absolute must-have.' Back then, they said, 'Otherwise, you'll have to take it all apart again very soon.'


You probably mean the splines on the transmission shaft? I have a dual-mass flywheel, maybe it's different there.
I made sure to grease it well. That way, the gears will slide smoothly onto the disc.