DMF replaced on DSG, now worse off...PLEASE HELP!!

Hi all, i just bought my first VW (06 jetta 1.9 TDI w/DSG) a few weeks ago w/114k and have been on this site quite a bit, seems like a great community.

When i bought my car i thought the transmission wasnt as it should be but ive heard DSGs take getting used to. Well i brought it in to the dealer for free inspection and they claim my DMF was failing (did notice the noise after knowing what to listen for even though it wasnt as bad as some here have had and car had slight free rev at lower rpm, also trans leaking. I didnt notice much if any leaking when i took of the bottom skid cover when i changed oil. I figured from reading around that the DMF should get changed out sooner than later so i tackled it yesterday with a DMF i bought from Aaron @ Boraparts.com.

Bad news - it seems worse than it ever has...
At first the car seemed fine pulling it out of the garage but then when i tried to drive away the tranny didnt want to shift smoothly until high revs and between shifting in/out of gears (mainly 2nd and 3rd) there is a grinding/vibrating sound and car doesnt feel like it has much power, keeps cutting out at about 2000rpm like a severe hiccup. At first i thought it was just the ECU relearning as it appeared to get better as i was shifting into sport and tiptronic and back to drive few times and then running good (about 5 miles of driving after fresh DMF replace), still seemed little under powered but didnt want to be pushing so maybe it was just me not givin it gas but was shifting good. Parked for a while and then it started to do the sever hiccup again next time i drove, and is still but it only seems to do it when its coldest (most noticeable even though it seems like its still weaker when warm..taking longer than norm to get up to speed) When it shifts it makes a grinding/vibrating sound like it free revs and grinds then shifts, when shifting in tiptronic it is smooth.

I did loose small amount of tranny fluid (1/6liter) at very very most, tried to remove the 3 bolts that held on the tranny cooler but they were all stripped from a previous job so i attempted to remove one of the hoses pinched but still lost little bit, pluged with finger and replaced hose. Left cooler on when replacing DMF. What i did notice about leaking trans fluid was it looked as though there was little wetness around trans filter housing as maybe bad seal but know i cant check fluid and prob shouldnt replace filter either without changing fluid all together.
Engine light came on but it was just for MAF and since cleared code. I did notice when i took the flywheel out of the packaging (new, LuK oem upgraded DMF) before installing that it had some play in it when rotating it, i would say about an inch but figured that was fine as it was new and threw it in, the one i took out had about half that but figured it was grinding/binding inside?? Reading around after it sounds as though 10mm max play is allowed, maybe the new one was less than an inch but for sure more than 10mm. Do you have any idea what might be my issue, bad new flywheel, loss of tranny fluid, something else??? Any input would be great.

Also i was thinking i should change the trany fluid but need a Vag-com or VCDS to perform, is there anyone that has one that could mail me one and ill mail back or borrow if theres anyone in the area, i live in north branch minnesota and cant afford one as i blew all my spare money on the DMF and wifes pissed i made car worse after spending $$.

Im mechanically inclined for the most part, mech. engineer and always grew up working on motors and small engines but this is way way over my head and am frustrated but open for any ideas..

EDIT: the first time check engine light came on i had it scanned and it read P0101 - Mass air flow vol..., and P0299 - unidentified fuel and air metering error from generic reader. cleared codes and rescanned after wiggling MAF connection and got P0102 for mass or vol airflow circuit low input, cleared all errors and check engine light just came back on after about 3 start-stops totaling about 30 miles. Limp mode??? it seems when i first start it has this shift problem and until i shift into S or tip it will then smooth out shifting but lack of power - limp mode that i hear in some posts???

Any help is greatly appreciated.
Thanks all for reading.
Josh

I'm guessing your new DMF is fine and you are simply low on trans fluid. The filter cap should not leak. This suggests the new o-ring was not installed correctly or the leak is somewhere else. Checking fluid is not that difficult -- just read the DSG filter/fluid change How To. There's a list of members with VCDS, I think it's in the TDI 101 section.

I don't have an answer for your grinding symptom. That concerns me.

Thanks for the response.
I disconnected the MAF and car ran good, no severe hiccup and no rpm jump when shifting (when the grinding/virbation noise was noticed).
I needed to shift using tiptronic though as D would rev high before shifting and it seems i might be in limp mode?-low power. Shifting seems really smooth in tiptronic and now just seems problem with MAF?
I plan to do a trans fluid/filter change within a week and clean MAF and reconnect prob tonight after work to see if this helps.

I took car out for lunch and car was shifting in D just fine, i did hear what seemed like a leak in a hose, inspected and it looked as though my lower intercooler hose was not fully connected. as i was in parking lot i didnt have tools to remover lower skid cover but will reattach when i get home and clean MAF.
I noticed the hissing/leak up to about 2000rpm after that it was like a sudden burst of power above the 2000 rpm mark

fixed

Alright, home and think car is back to normal. The loose intercooler hose below the airbox was out of its socket and i connected in and cleaned MAF sensor w/CNC cleaner and car works great. I didnt have cruise control earlier and after this, cruise is working again too, shifting smooth and when it should. Thanks for the help/recommendations, next step change trans fluid and ill be set for a while, till TB service is needed, or camshaft

Sorry for the stupid question but what is a dmf?

lowhpdiesel said:

Sorry for the stupid question but what is a dmf?

Click to expand...

DMF is Dual-Mass Flywheel.

Does changing he dmf keep the trans from shifting funny?

reason i changed it was the trans was free rev'ing and dealer diagnosed from their road inspection that the DMF was failing. I wanted to replace to avoid it shattering and putting a hole in my DSG as others have seen. It did help it shift smoother now than it did before. At first i thought it was normal as my first DSG but with 113k miles was kinda questioning it when i bought it. I had a hiccup at 1800-2000 rpm but fuel filter helped that and now the new dmf, car shifts perfectly.

Another dumb question, what's dsg? Also how hard are the dmf to change?

it keeps the transmission connected to the engine, more along the lines you'll notice sounds from the DMF before failure as well as some jerykyness. Search google for DMF failure there's a welth of info.

Shifting funny would lead more to fluid/controler issue.

I'm having almost the identical issue. I've had the cam and lifters replace, dmf replaced, fuel and air filter replaced, and 4k later it still is not shifting correctly until after burst of power at high rpms... 2006 tdi dsg tranny. I'm trying to check vac hoses and intercooler piping, but i'm not 100% where all to check. please help, only had the car for 3 months... also loss of mpg after flywheel was replaced. Thanks

also when the problem occurs, i lose power very badly and then when it finally goes i get lots of black smoke. thanks again.

Possibly the turbo actuator.

how could i rule out the actuator? I did notice that the air intake that goes into the intake manifold is pretty wobbly. maybe that is contributing? also was reading that some were having issues with exhaust side turbo leaks that were causing loss in power and irregular shifting. seems to be a pain to get to the turbo. easier to access from the bottom? thanks.

Guys, just the level being wrong on the DSG's can cause significant shift/operation problem in the DSG...Ask me how I know..

Always start there with anykind of shifting problems...

KRAMIT...you have "none" on your TDI list and you didnt say in your post what car you have. That info would really aid someone trying to help. You dont want advice or waste time inspecting something that is not relevent to your model.
Sorry I dont have any info for you, I'm still learning myself.