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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKV-A5 Golf/Jettas

VW MKV-A5 Golf/Jettas Discussions area for A5/MkV Jetta/Golf (2005/2006 PD and 2009 CR).

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Old February 16th, 2018, 10:59   #1
spatuality
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Location: Ontario, Canada
Fuel Economy: 5.8L/100KM
Unhappy Bottom end blow out

Hi forum,

Short version:
The bottom end of my Jetta clunked a few times and dropped what smells like transmission fluid everywhere.

Useful info:
2006 1.9L BRM 5M. 250k KM. Stock clutch/dmf has been rattling at idle for a couple years. Slight slipping of clutch felt a couple times this year. Transmission fluid changed at 236k KM in May with Fuchs Titan Sintofluid FE 75w. Slight clunk felt when foot off accelerator in 2nd for the last year, but figured it was LCA bushing, maybe an engine mount. Never had a leak of any kind.

Long version:
Wife was out with the car, put it into neutral stopping at a light, and there was a big clunk, like when you drop the clutch in gear while holding the brake. But the enginge did not stall. No hiccups with the engine at all she says. Not even an engine light. Put the car into first, couldnt make it move. Shut it off/on 3 times, still wouldnt move. Blocking busy intersection at this point, and freaking out she called me. The car had been off for a couple minutes at this point. I had her start it, it went into gear, and she drove the 3KM home without issue.

Parked in the driveway, and saw fluid dripping steadily behind the bottom engine cover. Started it up no problem, reversed a few feet, putting it into first felt 'empty', like the clutch wouldnt engage. It clunked and I put the clutch in again, then genty let the clutch out in first, and drove it 20m into the garage.

Car is now on jackstands, oil absorbant powder and oil drain pan under it. I will get under it in a couple hours to pull off the engine tray.

I'm making a guess the DMF failed and the clutch wont engage on the bits that are left. There must be some transmission lines inthe bell housing that got hit with shrapnel? But the engine is running normally. Not even CEL. I would of thought it would shake and shudder like crazy, or rattle very noticably.

Any initial direction where to look to figure out what happened?

Last edited by spatuality; February 16th, 2018 at 11:23.
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Old February 16th, 2018, 11:46   #2
aja8888
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Quote:
Originally Posted by spatuality View Post
Hi forum,

Any initial direction where to look to figure out what happened?
Flywheel.....
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Old February 16th, 2018, 11:53   #3
spatuality
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With all the fluid coming out, what else likely got hit to cause a leak?

Just a seal somewhere, or bent / pierced something?

Just trying to plan for what to order.

I figured a SMF, clutch, throwout bearing, fork, and now I guess transmission fluid.

Maybe a rear main seal now too? Hopefully the shaft isnt bent...
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Old February 16th, 2018, 12:10   #4
banshee365
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If you had a catastrophic flywheel failure it’s possible that’s your trans case is cracked which is where all of the fluid is coming from.
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Old February 16th, 2018, 12:10   #5
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You really need to take it apart to assess the damages before ordering anything. The transmission case could have been compromised or a shaft seal is leaking. The bell housing could be damaged also.

There would be no engine codes indicated since it's a manual transmission. Most codes are emission related anyway.
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Old February 16th, 2018, 12:47   #6
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Just did mine and looked the same, the followers had dishes in them.
Went with the ID parts billet cam and used the myturbodiesel writeup.
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Old February 16th, 2018, 13:39   #7
aja8888
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Just did mine and looked the same, the followers had dishes in them.
Went with the ID parts billet cam and used the myturbodiesel writeup.
I think you posted in the wrong thread.
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Old February 16th, 2018, 14:33   #8
spatuality
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Sitting on the engine tray is shrapnel.

Theres a hole matching the shrapnel on the right rear lower side of what I guess is the transmission bell housing?

I just noticed the picture looks like there's 2 holes. I'll have to get inder here again later to see.

Pictures below.

Is this bell housing replaceable, and the internals cleanable?

Costs are probably about to exceed resale value...






Last edited by spatuality; February 16th, 2018 at 14:41.
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Old February 16th, 2018, 14:52   #9
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Time to source a second hand trans.
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Old February 16th, 2018, 15:03   #10
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Time to source a second hand trans.

And a few other parts.
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Old February 16th, 2018, 15:23   #11
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Quote:
Originally Posted by aja8888 View Post
And a few other parts.
True story.
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Old February 16th, 2018, 15:50   #12
spatuality
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Thanks for the quick replies everyone. You're awesome.

So if the shaft isn't bent, a new SMF, clutch, throwout bearing, fork, transmission fluid and all the replacement bolts a clutch kit comes with.

A used 5sp transmission. I'm guessing a gasket of some kind and a few more bolts.

Maybe a rear main seal and crank position sensor while I'm in there.

It's got the brm cam shaft and lifter tick, and a bit of oil escaping the turbo.

Is there a reliable source of rebuilt transmissions for this car? Or pointers to know if a used one is ok? Worth sticking in a 6sp and/or LSD diff while I'm in there?
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Old February 16th, 2018, 15:56   #13
spatuality
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It's not worth trying to clean out whatever is inside that bell housing? Too likely to have metal bits all over it? Housings aren't available in their own?

Just trying to wrap my head around options for this few thousand dollar repair.

Or maybe it's time to part out what's left and move on.

Last edited by spatuality; February 16th, 2018 at 16:06.
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Old February 16th, 2018, 16:13   #14
banshee365
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I would replace the trans and cam and keep driving. If your followers are making nosie you are well beyond needing a cam and arguably oil pump.

And don’t touch the rear seal if it’s not leaking. It requires an expensive special tool to install

Last edited by banshee365; February 16th, 2018 at 16:43.
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Old February 17th, 2018, 06:34   #15
tactdi
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Look into a 6SP manual transmission swap. I did, for a little more money than sourcing a used transmission,
I purchased a kit from one of the vendors that posted conversion kits in the Vendor forum. Included everything but transmission
and brake fluid.

While I had the transmission out, I replaced the EGR Cooler, much easier to get to all the bolts and
coolant hoses with the trans out.
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