Touran Rattling Noise: Causes & Fixes

I'm not sure if this is the right section, but I'm going to describe my problem.
Touran 2.0 TDI, 2005, Engine code: BKD, Gearbox code: unknown, 15,000 km.

After driving 800 km continuously, shortly after refueling, I noticed a faint rattling sound coming from the front of the car while driving uphill at approximately 120 km/h.

After that, I briefly tested the conditions under which the rattling occurs.
It only occurs under load, and only in the 4th and 6th gears. Naturally, I drove home in 5th gear: there was no rattling or unusual noise there.

Over the next 200 kilometers, the rattling noise became louder, and it turned out that it also occurs when I'm in gear and releasing the clutch as the engine accelerates. So, it happens under acceleration load and under heavy braking load.

The rattling sound, which was initially faint, eventually became a loud 'RRRRRRR' that could be heard even with the window open.

Okay, I don't have the details about the drivetrain in my head, but maybe one of you does?
What could the 4th and 6th gears have in common, and what could be rattling?

Okay, regarding the climate control, engine issues, I'm probably ruling those out for now!

If there was a problem with the drive shafts, it would rattle in all gears.

Does anyone have any ideas?
Thank you, Chris.

"The transmission, and everything else, would rattle in all gears. Things like the clutch, dual-mass flywheel, and drive shafts..."
I've had a bad experience: "Touran 6th gear" is currently my favorite word.

Transmission, all other things would rattle in all gears. Like the clutch, dual-mass flywheel, drive shafts...
I'm a seasoned veteran: 'Touran 6th gear' is currently my favorite word.


hello klaus,


'I'll take a look tomorrow and check that screw. That might explain the symptoms. Is it a standard Torx screw? Is there anything I should be careful about when removing the cover? Like, will anything fall out (besides oil, of course)?'

Thank you!

Hello Chris, unknown.
Remove the battery and casing, support the transmission from below, and drain the oil.
Set screws, multi-tooth. You can only reach the two top ones with a special tool.
The multi-spline nut is 14 mm for the two micro-encapsulated screws.
To disassemble the 5th or 6th gear group, you need a bell housing removal tool. Otherwise, you risk damaging everything.
I think that if there are problems, even in 4th gear, the gearbox needs to be removed and disassembled! You can access the 5th/6th gears easily from the left side of the wheel.
The sixth gear needs to be removed as well to access the synchronizer hub.
Don't think tightening the screw, which may have become loose, will fix it . The 4th gear is the problem area.
"Some oil is leaking, so place a 5-liter canister underneath to catch it. It's best to pour the oil back into the rear part of the transmission through the open lid before closing it."
Make sure to switch to the next speed (5/6) with the lid open.
If a 6th gear is needed, the 6th gear itself must also be ordered and installed! Otherwise, the old gear will jam with the new module, resulting in noises and significant heat generation!
Good luck, and feel free to reach out.

So, I removed the inner fender lining today and saw that the transmission looks completely different. It's a 3-shaft transmission, KB: HDU (same as JLT). You only see a black metal cover, behind which you can see the end of a shaft with a retaining ring.

Here's a picture:
http://www.automatik-schaltgetriebe.de/getriebe/hdu/b0763039c250554d0f3.jpg

Hi Chris, sorry, but there are other types of transmissions besides my ERF... Unfortunately, I haven't been able to open your 3-roller assembly yet, and I still suspect that it needs to be removed in order to repair it.
Have you found out anything yet?

Hello Chris, sorry, there are other types of transmissions besides my ERF... unfortunately, I haven't opened your 3-roller part yet, and I still suspect that it needs to be removed in order to repair it.
Have you found out anything yet?

I'll probably take it out next week.

Someone from another forum mentioned that a gear needed for the 4th and 6th gears is broken (approximately €300).

The gearbox repair specialist near us said that if he replaces any bearings (which costs €500), he will replace all of them. And if necessary, he will also replace any defective gears (which would cost an additional €1000).

I could get a used one for €850, supposedly with 50,000 km on it.

I'm not really sure what to do.

What do you think, how long will the engine and the rest of the car last?

If the engine fails after 20,000 km, then...

Used transmissions? With a warranty? See my brother-in-law's Touran:
AT (Automatic Transmission) cost 1400.-. The 6th gear popped out after 150 km. Parts without labor cost 350.- €. They could take the transmission back, maybe the problem is due to the installation.
If you have access to specialized tools and Elsa, and possibly some experience with tinkering, try doing it yourself.
Or.
Have the used part installed by the supplier. If it breaks down, you can take it back under warranty. Otherwise, you'll be stuck with the removal and installation costs if you have further problems, or they might try to blame the faulty installation if the installer is different from the gearbox supplier.
I would prefer to handle it myself.
Have you ruled out all other possibilities?

In the 02M and 02Q transmissions, the 4th and 6th gears share the same drive pinion. Because this pinion is only used in these two gears, damage to this pinion is a likely cause of the problem.

Yep... this one gear was missing 3 teeth!
He didn't say it directly, but it seems like it's not an isolated incident.
VW pays 50%, but I'm still stuck with the €1500 for the automatic transmission! :-/

This is the drive gear for the 4th and 6th gears.
Why AT transmissions? It's known to be problematic, so why isn't it being fixed?

This is the drive gear for the 4th and 6th gears.
Why AT transmissions? It's known to be a problem, so why isn't it being repaired?

I can't do it, and I don't have the time to learn how. The workshop isn't willing to take on the job (for the price of an AT), and an ATG with a 2-year warranty for 1500 [currency] is also something to consider!

engl wrote:

Getriebebauer wrote: This is the drive gear for the 4th and 6th gears. Why an AT (automatic transmission) gearbox? It's exposed, so why isn't it being repaired? I can't do it, and I also don't have the time to get properly involved. The workshop doesn't dare to do it (for the price of an AT), and an ATG for 1500 with a 2-year warranty also has something to offer!

It's quite strange that suppliers were already able to manufacture gears 25 years ago that were durable.
It seems VW saved money in the wrong places.

At the workshop where I work in Nuremberg, we have 2 mechanics who repair these transmissions very often. Of course, only if the cost of the repair is less than the price of a new one.

It's quite strange that VW every day alone produces 11,000 transmissions in the German transmission plant, and you want to question the long-standing experience (VW has been manufacturing its own transmissions from the beginning!) because of a few defects?
Please don't misunderstand, any damage is too much! That's how we see it, but we are also realistic enough to know that with any product designed and manufactured by humans, there is always a possibility of a defect. And every manufacturer expects a certain failure rate.

I don't understand the workshop's approach. It seems like all that's needed now is to replace the entire shaft, part number 02M 311 101 AE, and then reassemble the transmission housing. It should only take about an hour of work. The parts cost is approximately €250.

I don't question their experience. If they wanted to, they could also build engines and transmissions that last a long time.
I'm afraid I don't know the percentage of transmissions that are defective.

However, at least 20 defective transmissions, intended for cross-installation in VW/Audi vehicles, are being installed.
Longitudinal-mounted transmission, suitable for A6, A4, A8, and 3B Passat models.
Multitronik is excluded.

I can hardly believe that the Welle 250 costs €250, especially considering that a single synchronous coupling with a sliding sleeve already costs €120.

Or has VW recognized the problem and already put together an affordable repair kit?

However, there is also praise to be given. If the gearboxes are not broken, they shift very smoothly, always.

Well, defects occur everywhere. And in a forum like this, they are gathered together. Which is understandable. What's there to discuss or fix if everything is running smoothly?

However, I haven't observed a significant number of major transmission failures in this context. That being said, it's true that two Touran transmissions failed within a short period.