VW TDI clutch question

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d55dave

d55dave

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So I have a chance to buy an 04 TDI for cheap. The car is in good shape but makes a loud clacking noise. The shop told the owner that it needs a clutch and flywheel. Aparently the dual mass flywheel has failed.

Does anyone have experience with these? Does the diagnosis sound right?

Any words of caution?

How hard is it to change the clutch, do I need any special tools?

What exactly is a dual mass flywheel? Does it have spring loaded balance weights?

Can I use an aftermarket standard flywheel and clutch? Are they any good?

I am thinking it would be a good ecenomical car for my son at university. Thanks for any and all advice!

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Googled it and found lots of pictures, and yes it is some sort of spring loaded assembly. This appears to link to a youtube video. By the way, I had a 2004 Jetta TDI wagon, and it was a great car. I have a 2015 Passat TDI as my daily driver.

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Hey, thanks qcuda. Yes, lots of info on the net. I am lookibg for some real first hand info from a car guy who actually fixes things, LOL. Thinking of fixing the VW as a car for ouf son who is going to university in Ottawa.
 
Great car for him. I used to get nearly 60 mpg highway, or up to 1000 km per tank. Have you priced the flywheel/clutch combo?
 
Update
qkcuda said:
Great car for him. I used to get nearly 60 mpg highway, or up to 1000 km per tank. Have you priced the flywheel/clutch combo?
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Yep. Looks like on rockauto I can buy the combo with the non weighted flywheel for 400 - 500. I am wondering how difficult pulling the transaxle is.
 
yup, my family likes VWs
(i even had a few myself, including a 1.8T passat with a reflashed ECU that held 18 PSI of boost all day long...hitting 3200 RPM like that car felt like getting rearended by a semi)

but yeah, the dual mass flywheels are almost a interval maintenance item
i not sure about that particular diesel engine, but research the timing chain
my gas engines were interval engines and the chain was RnR was just shy of a thousand real dollars (probably more your side of the falls)
so be sure to check if that needs to get done soon or not
 
Yes, timing belts on those models are to be changed every 100,000 km. Not rocket science, but it involves removing everything on the passenger side of the engine, so usually figure on a new water pump at the same time.
 
d55dave said:
Perfect, good to know. Thanks guys
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one more thing, if that particular car has a push button parking brake, then your rear brake calipers will have an electro motor to adjust then
the VW garage will tell you the only way to back that motor off to get new pads on, is to bring the car in and have them hook it up to their computer
what they will not tell you is that you can disconnect the electro motor and simply hotwire any 12 volt signal to it to back them off, so you can replace the pads yourself and save the 150 dollar an hour shop rate they will charge you
 
I have an 04 and I love it! I haven't dealt with the clutch because mine came with a new one. But I just did the timing belt and water pump recently and it was pretty easy. You need a special tool to do it right though.

Also the 04 is the Pumpe Duse motor. The previous ALH motors were known to be more reliable, but its still a good car. Mine has 315k KM on it and its running strong.
 
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I never owned a TDI, but I do own a 1997 Jetta 2.0 5-speed. Luckily my Jetta's original clutch is still holding up well even at 110,000 miles.

These cars are like any other FWD car with a manual transmission. I do not believe you need any special tools for it, but make sure you get the right replacement parts for it! I would replace the clutch, flywheel and throwout bearing.

Nice score by the way! Those cars a long time, just beware the electrical systems on them when they get old.
 
Did the deal today. I bought it for 500 CDN, that is aprox 400 USD. The car is a little dirty but looks in good shape overall. There are only a few small dents and blemishes, zero rust. It has 280,000 km (174,000 miles). Not a spring chicken but also not too high for a diesel. It seems to run good other than the clatter from the broken flywheel weight.

Should be good transportation for our son. I will bring it home tomorrow and have a good crawl over it.
 
Go with a replacement dual mass flywheel. I've gotten rid of the 23+ pound dual mass flywheels on BMW's for a lighter 8.5 pound single mass flywheel. The transmission always "chatters". It's worse on hot days and/or with the A/C on. It sounds AWFUL. It's fine in gear while driving or with the clutch pedal pressed in. A single mass is ideal for performance use and is typically cheaper but not great for a daily driver.

I've never had a dual mass flywheel fail. Just the clutch go bad and burnt the flywheel. My current BMW is north of 400hp with plans to go higher. The clutch is worn and can't handle the power level. Some people have found the flywheels to fail around 500hp so I will probably go with a single mass flywheel again and deal with the annoying chattering.
 
1994redram said:
Go with a replacement dual mass flywheel. I've gotten rid of the 23+ pound dual mass flywheels on BMW's for a lighter 8.5 pound single mass flywheel. The transmission always "chatters". It's worse on hot days and/or with the A/C on. It sounds AWFUL. It's fine in gear while driving or with the clutch pedal pressed in. A single mass is ideal for performance use and is typically cheaper but not great for a daily driver.

I've never had a dual mass flywheel fail. Just the clutch go bad and burnt the flywheel. My current BMW is north of 400hp with plans to go higher. The clutch is worn and can't handle the power level. Some people have found the flywheels to fail around 500hp so I will probably go with a single mass flywheel again and deal with the annoying chattering.
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Good to know, thanks. Mine sounds exactly like the jetta in the YouTube video earlier in this thread. I am fairly certain the flywheel is failed..... will find out !
 
Dual Mass VW fails are common when they're subjected to the turbo gas guys early on, I changed one at a fairly low mileage, plate was in like 7 pieces. Not easy, but
not a nightmare either, just make sure You've got triple-square bits handy etc......................
 
Well I got it home and cleaned up. Man were the POs dirty. You wouldnt believe the french fries, makeup, camping gear, precriptions, a digital camera, toys, umbrellas, coffee mugs, cds, dog related items, a department store credit card and christian literature that came out of this thing. The PO is a true member of todays disposable, could care less about taking care of and fixing things society.

It is actually a pretty nice car, seems to run fine, the turbo spools and the ac even works. Now I am watching youtube videos on how to pull the trans and waiting on my new clutch kit to arrive.

I need to find one center cap, a spare tire and jack for it.

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