06 TDI DSG Transmission Failure at 65k?????!!!

Jim E.

Member
Joined
Nov 15, 2005
Great News. VW Will Cover The Whole Repair!

I just got great news from my service rep that VW will cover the whole replacement of the tranny!
I must say, notwithstanding the tranny failure (which was still driveable), the experience overall was quite positive. VW always called me back whenever they set a time limit and they were very professional and courteous throughout this claim.
It's also important to note that I kept each and every receipt for service which I kept up with religiously.
I did complain about a noise coming from the car at 52K but they did not find anyting. My guess is that this was the start of the failure.
Cool!
 

Rod Bearing

Veteran Member
Joined
Sep 18, 2007
Location
Fort Worth
TDI
Several
I'm told "the flywheel exploded and caused the transmission to fail.

Jim E. said:
I have an 06 Jetta TDI --- I'm told "the flywheel exploded and caused the transmission to fail. Has anyone ever heard of such a failure???
Any advice as to how I should handle this?
Thanks,
Jim
I changed the title to reflect the actual reality, Jim. ... which I had happen as well. Mine even took out the engine. The engine AND the transmission suffered but they were running before the flywheel puked.

The transmission didn't fail, Jim. It was ruined by a POS flywheel design.
 

Ted Hurst

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Location
44224
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2015 GSW
Jim E. said:
I just got great news from my service rep that VW will cover the whole replacement of the tranny!
I must say, notwithstanding the tranny failure (which was still driveable), the experience overall was quite positive. VW always called me back whenever they set a time limit and they were very professional and courteous throughout this claim.
It's also important to note that I kept each and every receipt for service which I kept up with religiously.
I did complain about a noise coming from the car at 52K but they did not find anyting. My guess is that this was the start of the failure.
Cool!
Wow! That's warm and fuzzy!
 

jasonTDI

TDI GURU Vendor , w/Business number
Joined
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Location
Oregon, WI
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20' RAM 3500 CCLB dually HO/Aisan. 2019 Cherokee 2.0T
If you see one of these flywheels you'd understand why the SMF can't be "bolted in" its a totally different fitment in the shaft design and attachment to the DSG. (splined)

However you can bolt a SMF and convert it to a manual. BTDT.
 

dzcad90

Rolex & gin
Joined
Mar 15, 1999
Location
Joliet, IL USA
TDI
Jetta - 97 (RIP), '03 (Sold), '09
SonyAD said:
Basically, VW and others fit DMFs to diesel passenger cars so soccer moms will buy them.

I think this statement is a little off..

We live in a world of constantly evolving technology and betterment. Why, if the technology exists, would we still be driving cars that jar you out of the seat vs. providing a smooth driving experience?

Though the DMF has it's issues, it's by no means an option to "only please soccer moms." If we just kept on with that line of thinking, we'd still be driving Model T's.
 

longo

Well-known member
Joined
Apr 6, 2009
Location
alberta
TDI
2006 Candy White, Beige leather, Pkg 2 DSG
Jetta Loyalists

I have just waded through 1000's of posts and points on the VW Jetta TDI's BRM engines grinding though Camshafts, lifters and other little bits of top end parts, and now this forum Discussion on Exploding DMF's!

OMG, how does VW ever sell a single vehicle to anyone these days?

I can see someone who is tottaly uninformed (as I was) buying a VW TDI, but now that I have one parked in the garage, I am shaking my head in amazement that most posters on these various 'VW Problems' links are repeat buyers!

I grant you that every vehicle maker has a few problems every year, But VW has most of them in their drivetrain..an expen$ive place to be trying to back engineer oil starvaton problems, bad parts design, or just plain ***!.

Mark 4, and Mark 5, have specific unresolved powertrain issues, and now I read that VW will be bringing out another new Jetta model this fall, only 3 years after introducing the Mark 6.

No thank you VW, I don't want to spend another 5 min. on a forum dedicated to a shopping list of dumb enigineering tricks and quality issues that cost thousands and thousands of dollars to patch up and still not fix.

My wife still drives a Nissan Versa that we bought new in 2007, it's been back to the dealership once in the past 3 years, to have the rear wiper blade adjusted.

Nothing 'ginding, rattlling, clunking, or exploding. Just start it up and off you go for another 5 thousand miles to the next $30.00 oil change, any 5-30W will do thanks.
 
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Lee_Taylor

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Sep 26, 2004
Location
Kent, England
TDI
Audi A3 1.4 COD
To be fair VW is not alone in having issues with dual mass flywheels. It is probably more obvious because they are one of if not the only manufacturer in North America that imports a small diesel. If you go through the UK press you will find plenty of examples of other manufacturers that have had issues with this lash up. The common factor would appear to be they are generally diesels that are affected.
 

Hurst89

Veteran Member
Joined
Feb 17, 2007
Location
Kentucky
TDI
2005.5 Pkg 0 5spd TDI
Just out of curiosity, would it not be possible to find a spring-centered clutch disk that has the same splines as the DSG input shaft, then just use a SMF set up with a pressure plate but no throwout bearing? This design was used and still is used on many tractors with powershift transmissions as a torque limiter and also to dampen any pulses from the engine. It may require a custom clutch center, but if you measure the diameter and number of splines, it shouldn't be terribly hard to make a batch of custom 228 mm clutch disks and then just use a G60 flywheel a strong pressure plate.

Hurst
 

Stibz

Veteran Member
Joined
Dec 26, 2005
Location
Philly
TDI
2000 Jetta, 2009 Jetta
longo said:
I can see someone who is tottaly uninformed (as I was) buying a VW TDI, but now that I have one parked in the garage, I am shaking my head in amazement that most posters on these various 'VW Problems' links are repeat buyers!

No thank you VW, I don't want to spend another 5 min. on a forum dedicated to a shopping list of dumb enigineering tricks and quality issues that cost thousands and thousands of dollars to patch up and still not fix.

My wife still drives a Nissan Versa that we bought new in 2007, it's been back to the dealership once in the past 3 years, to have the rear wiper blade adjusted.

Nothing 'ginding, rattlling, clunking, or exploding. Just start it up and off you go for another 5 thousand miles to the next $30.00 oil change, any 5-30W will do thanks.
Well, it's a Versa!?! A bottom-of-the-barrel subcompact (throw-away cars). It's one of the most simplistic cars sold. There's nothing wrong with that, but they're two very different machines.

I'm a repeat VW buyer, and I've been on the forums for several years before I purchased our '09, with a DSG. Obviously, people complain on here more than they praise, and they also panic. There are plenty of VW TDI owners with little to bit*h about, and are pretty happy with their cars. I'm one of them. So what it takes a special oil??? I'll see you when I hit 500k, and you're on your 4th Versa.
 
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longo

Well-known member
Joined
Apr 6, 2009
Location
alberta
TDI
2006 Candy White, Beige leather, Pkg 2 DSG
"I'll see you when I hit 500k, and you're on your 4th Versa"


No you won't Stibz, atyour current rate of miles you will hit 500,000 about the year 2022 you will have gotten bored of it long before that, and the way California keeps tightening up the emmisson rules to push out Diesel engines, the only VW TDI around then might be in a museum sitting next to a 1957 Beatle.

And (someone in the family) will still be driving our 15 year old Versa.
 

Stibz

Veteran Member
Joined
Dec 26, 2005
Location
Philly
TDI
2000 Jetta, 2009 Jetta
longo said:
"I'll see you when I hit 500k, and you're on your 4th Versa"


No you won't Stibz, atyour current rate of miles you will hit 500,000 about the year 2022 you will have gotten bored of it long before that, and the way California keeps tightening up the emmisson rules to push out Diesel engines, the only VW TDI around then might be in a museum sitting next to a 1957 Beatle.

And (someone in the family) will still be driving our 15 year old Versa.
On the 2009, you might be right. On the 2000 TDI, try 2 years or so...I have over 400,000 now. This might be a good time to tell you that our 2009 has been completely trouble-free.
 

SonyAD

banned Borat
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Nov 15, 2009
Location
București, România
TDI
Peugeot 206 2.0 HDi
dzcad90 said:
I think this statement is a little off..

We live in a world of constantly evolving technology and betterment. Why, if the technology exists, would we still be driving cars that jar you out of the seat vs. providing a smooth driving experience?

Though the DMF has it's issues, it's by no means an option to "only please soccer moms." If we just kept on with that line of thinking, we'd still be driving Model T's.
Nope. If VW, or any manufacturer that fits DMFs to their inline4s, actually cared about NVH they'd chuck up another 2 or at least 1 pot in the line. Or make a boxer diesel.

But most are simply far too cheap for that. The DMFs fail in quick order, not just on VW vehicles. Sooner than you'd need to change the clutch kit with a normal flywheel. Trouble is, if they fail catastrophically they're bound to at least also damage the bell housing.

Lee_Taylor said:
To be fair VW is not alone in having issues with dual mass flywheels. It is probably more obvious because they are one of if not the only manufacturer in North America that imports a small diesel. If you go through the UK press you will find plenty of examples of other manufacturers that have had issues with this lash up. The common factor would appear to be they are generally diesels that are affected.
VW isn't the only one. And they're a source of fail anywhere they're used. PSA also uses them, that I know of. And also Renault. Alfa Romeo as well, etc. They're bollocks, no matter the brand or car.

Dual mass flywheels are fitted to diesels to reduce NVH. But if they could fail on gassers without being fitted to gassers I'm sure they would oblige.

Stibz said:
Well, it's a Versa!?! A bottom-of-the-barrel subcompact (throw-away cars). It's one of the most simplistic cars sold. There's nothing wrong with that, but they're two very different machines.
I take exception at your comment. Please don't disparage subcompacts or other makes. My 2000 Peugeot 206:



The 206 used to be offered (MY 2004-2006) with a 1.6 hdi, 110 PS though the engine has been available since at least 2003. DOHC 16v, VGT, intercooled, CommonRail direct injection, roller rocker valvetrain as all hdi engines I know of. Only thing it didn't have, in terms of powertrain, was a particulate filter. In terms of drivetrain, a mechatronic/sequential syncromesh or DSG but I think you could buy it with a torque converter automatic.

I think VW introduced a comparable 1.6 tdi in second half of 2009.
 
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TwoTone

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DMV
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05.5 Jetta (sold)
dzcad90 said:
I think this statement is a little off..

We live in a world of constantly evolving technology and betterment. Why, if the technology exists, would we still be driving cars that jar you out of the seat vs. providing a smooth driving experience?

Though the DMF has it's issues, it's by no means an option to "only please soccer moms." If we just kept on with that line of thinking, we'd still be driving Model T's.
Well if this is true, why doesn't our Jetta jarring me now since putting in the SMF?
 
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TwoTone

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DMV
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05.5 Jetta (sold)
Stibz said:
... This might be a good time to tell you that our 2009 has been completely trouble-free.
Wow a whole 41k trouble free. See the irony here, 41k trouble free on the new Jetta's is something to brag about. God luck on hitting 500k with it.
 

Stibz

Veteran Member
Joined
Dec 26, 2005
Location
Philly
TDI
2000 Jetta, 2009 Jetta
TwoTone said:
Wow a whole 41k trouble free. See the irony here, 41k trouble free on the new Jetta's is something to brag about. God luck on hitting 500k with it.
I'm not saying that to brag, obviously it's low mileage. I'm trying to point out that there ARE many '09 owners out there who aren't having any serious issues. More people come onto forums when they have an issue, looking for an answer to a problem, so that's more of what you see on here.

Unless the car is in a serious accident, I'm 100% sure that it will pass the 500k mark, it's just a matter of time. I'm sure that the original DSG won't last THAT long, but that's something I'm fine with. Tranny swaps aren't so painful, and it's still cheaper than buying a new car every 100k or 150k.

SonyAD: Sorry, not trying to disparage all subcompacts, but on your side of the puddle, you have higher-end, higher quality subcompacts than we do here. We've only recently started to see really nice small cars here in the states. When I think subcompact here, I think ford fiesta and geo metro...lol. In a way, I guess I throw the Versa in that category...cheap throw-away cars.

By the way, I see you're in Bucharest...I was born here in the states but I have family in Satu Mare.
 

Mrrogers1

Veteran Member
Joined
Jun 25, 2006
Location
Omaha NEEEBRASKA
TDI
2011 Golf TDI 6MT, 2011 Jetta TDI DSG, 2015 Golf Sportwagen S TDI DSG
oilhammer said:
Well, nothing to be scared of, just keep a close ear on any noises at idle from the bellhouse area, and if you hear any, replace the DMF right away.

At 85k miles, your DSG oil should have just been replaced for the second time (80k), and that is when I usually get a good listen, because I have the car idling over my head as I adjust the ATF level.
Ok, I have 78,000 trouble free FUN FILLED and fuel efficient miles on my 2006 DSG... and get this, no cam shaft wear either! :D No sounds, no clunking issues as of yet BUT I'm wondering if you can devulge what a DMF replacement would cost as a preventative measure? I did my DSG flush a little late (at 60k) and everything looked and sounded fine so I'll do it again when I do my TB but if I wanted to take care of the DMF before then, sounds or not, would we be looking at about $700 + labor??

I really love my DSG TDI and I'm all for preventative maintenance ESPECIALLY if it means saving the kind of money the whole tranny costs. :(

ETA: Just backed out of this thread and thumbed through the old original thread to see what was new and found this post http://forums.tdiclub.com/showpost.php?p=2834915&postcount=66.

Thanks!
 
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longo

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Joined
Apr 6, 2009
Location
alberta
TDI
2006 Candy White, Beige leather, Pkg 2 DSG
Throw one my way!

"When I think subcompact here, I think ford fiesta and geo metro...lol. In a way, I guess I throw the Versa in that category...cheap throw-away cars."

My son bought a new Geo Metro back in 1994, (did you know it was built by Toyota?) the Green Hornet we called it, paid about $8,000 for it brand new. He drove it to work every day for years until it needed new tires, battery and a windwhield replaced.
His family had grown to Mini Van proportions so he sold it locally and thought that was the end of it...the new owners drove it for another 6 years and then re sold it locally, again.

It's still out there purring up and down the road with God knows how many miles on it, at 50 mpg.

They always hear from their 4 kids..."why didn't you save that car for one of us"?

Now the old GEo Metro's are hot items as buyers everywhere are looking for them for commuter cars that get from A to B on a 3 1/2 quart oil change and 1/2 gallon of regular gas.

We have never owned a Ford Fiesta, but I see them on the road everyday.

As for our Versa, trust me, it won't be 'thrown away' either.

We will need it for when the Jetta TDi is in for it's $129.00 VW 'approved' oil and filter changes, $450.00 DSG fluid changes, its $800.00 Timing belt changes, it's $1800 cam shaft replacement, or its $2000.00 DMF overhaul, (if we catch it before it "explode$).
 
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jasonTDI

TDI GURU Vendor , w/Business number
Joined
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Location
Oregon, WI
TDI
20' RAM 3500 CCLB dually HO/Aisan. 2019 Cherokee 2.0T
The metro is a suzuki, not a toyota. And talk about a loud, crap driving death trap....
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
longo As for our Versa said:
'thrown away'[/I] either.
....
When the timing chain tensioner self-implodes on itself and the vario-cam phaser eats its way into the side of the head rendering the entire engine useless and you see how much it is to replace it, you may retract that statement.

We service a bunch of Versas for a fleet (Walgreen's). They are indeed a throwaway car. :cool: But, for $9000 what can you expect, really?
 

longo

Well-known member
Joined
Apr 6, 2009
Location
alberta
TDI
2006 Candy White, Beige leather, Pkg 2 DSG
Picking on the Metro

. :cool: But, for $9000 what can you expect, really?

Well Oilhammer, for $9000 I guess I would expect that might cover my 2006 Jetta TDI repair bill when the DMF explodes, shreds the DSG and jams up the motor.

(BTW my Sons 16 year old Metro/Suzuki, thank you, is still running on it's original 3 cylinder engine)

If you know of some car brands from the last few years that have no faults, PLEASE post your thoughts.

(2009 JD power survey says, for best reliability, "buy a Buick" or a Hyundai)
 
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esteeze

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Joined
May 29, 2006
Location
Hoover, AL
TDI
06.5 Jetta TDI
longo said:
. :cool: But, for $9000 what can you expect, really?

Well Oilhammer, for $9000 I guess I would expect that might cover my 2006 Jetta TDI repair bill when the DMF explodes, shreds the DSG and jams up the motor.

(BTW my Sons 16 year old Metro/Suzuki, thank you, is still running on it's original 3 cylinder engine)

If you know of some car brands from the last few years that have no faults, PLEASE post your thoughts.

(2009 JD power survey says, for best reliability, "buy a Buick" or a Hyundai)
(keeping fingers crossed that the DSG lasts on my 06 Jetta TDI)

I had a 93 Honda Civic for 10 years that was bought new (for about $15,000 in 1993); it was pretty fault free. Over 150,000 miles, I put a timing belt/water pump, 2 sets of tires, 1 set of brakes, and 1 battery in it (along with oil and other fluid changes, of course). It was a 5 speed, and had the same clutch on it when I sold it after 10 years. That was a good one.
 

longo

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Joined
Apr 6, 2009
Location
alberta
TDI
2006 Candy White, Beige leather, Pkg 2 DSG
Non DSG cars we have loved

ESTEEZE,

I can only think of a few great little cars from the 90's and your pick of the early Honda Civics is right on. Our neighbor bought a 92 Civic Hacthback that seemed to make gas as it ran..

2 doors, folding rear seats and a little engine that reved happily away as you stirred though the gears going through traffic.
In my mind they were the perfect transportation solution for simple A to B drives, but do recall once when they brought home a new automatic washing machine in the back, and the hatch lid was even closed!

The Geo Metro was a very poor immitaion of the Honda Civics at the time, but if you went for the 4 cyl engine you could get one with an automatic. and a few more tiny little horses under the hood for a few thousand less than the Honda.

Most people still owning those early fuel sippers are carefully preserving them and tho they don't look like eggs on wheels like everything else these days, I think that's a plus.

For the repair/service bills on the modern TDI's and the horror stories of the VW dealership experience, it's just too bad that there are still very few inexpesive alternatives if you are looking for great MPG's.

Hybrids? not for me thanks.

Our Nissan Versa has been faultless (so far) thanks for the heads up Oilhammer) as according to him, it's engine is grinding itself into little pieces as well.

I'm hoping the new 2011 VW's will have resolved all the expensive power train repair issues inherent in my 2006 JETTA DSG TDI.
 

Windjammer

Veteran Member
Joined
Jun 18, 2006
Location
Cinti, OH
TDI
MK4 & Mk5
Still trying to figure out why lomgo is driving a pos Jetta TDI when he could drive a honda, metro, hyundai etc..:rolleyes:
 

BeauTDI

Active member
Joined
Dec 27, 2009
Location
MO, USA
TDI
2010 JSW TDI
Holy cow if I'd read half of this stuff last year I probably wouldn't be driving my new TDI! Call me an optimist, I've had good fortune (knock on wood) with vehicles and basic DIY maintenance. It's a machine, some of them break... hope VW rogers up to any systemic issues. Honestly, thanks for sharing your experience and knowledge with the rest of us.

Had to laugh about the Chevy Metro comments... still have one I bought in '99 for all of $7200. Think it was $8400 after financing, and all I've done is changed the oil, muffler, tires three times and battery once. Oh, and the side mirror that fell off twice... kind of glued that back on. Thing has averaged 40-45 mpg lifetime doing 70mph commutes.

It's probably been the most "efficient" investment I ever made... but it surely is a loud, tin-can rattletrap with all three mighty cylinders straining for all their worth... with two or more people inside and going up a long hill it's hard to get past 35mph... does have airbags though, as if they'd be any good :D
 

SonyAD

banned Borat
Joined
Nov 15, 2009
Location
București, România
TDI
Peugeot 206 2.0 HDi
Except for first gear synchronizers, manual transmissions might be mistaken for immortal. Especially if you change the oil every so often and add MoS2.
 

longo

Well-known member
Joined
Apr 6, 2009
Location
alberta
TDI
2006 Candy White, Beige leather, Pkg 2 DSG
Need Therapy

Windjammer said:
Still trying to figure out why lomgo is driving a pos Jetta TDI ..:rolleyes:
Since reading all the other posts on BRM engine, transmission and flywheel probelms, I'm not.

The Jetta is sitting in the garage while I try to figure out what to do with it.

I don't have the stomach to sell it to anyone locally, I have to live here too. I guess it will end up as a trade in, somewhere far from home.
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
I personally think some of the best cars, by any manufacturer, have already been built, keeping in mind what they were in their day, and some of my opinions are based on those with experiences senior to my own.

Some of my top picks from some of the bigger manufacturers:

Toyota:

1980 through 1983 Corolla (the rear-drivers)
1990 through 1997 Corolla (4A-FE)
1987 through 1991 Camry (3S-FE)
1990 through 1994 Celsior (sold here as the LS400)
1998 through 2005 Aristo (sold here as the GS300/400/430)

Nissan:

Any VG30-equipped car or truck, from about 1985-on (this excludes most any newer Nissan). Like a 1993 Maxima... excellent car.
The last of the rear drive 200SX was a very good car, as was the mid to late '80s Stanza, with the twin-plug belt driven 2.0L SOHC engine.

Mazda:

1986 through 1993 B-trucks (I personally drove one of those to over 400k miles before a deer tooefed it).
1985 through 1991 626.
1985 through 1994 323/Protege, with a special nod to the 1991-1994 Protege as those were a fantastic little car for the money.
First generation 929 (the boxy one, with the SOHC 3.0L).
First generation V6 MPV (same engine as the above 929).
...most anything after that started to go downhill, with Ford's influence ultimately spelling the demise of the "old" Mazda.

Honda:

Any Civic prior to 2001 is a great car. 2001+ are crap piles in comparison, sorry. :eek:
Accords through 2002, with the 1991ish models probably being the best all around car (this was the car that really put the Accord on the map).
The Legends were stellar cars in their day, an all-around top notch car, especially the earlier ones (1985 - 1988).

Mitsubishi surprisingly has pulled together more recently, I would say they have some of the better stuff they have ever had in recent years. I have to say, I just drove my 1995 Mitsu on a 3000+ mile trip and it performed well, though. ;)

Ford:

They may have their best stuff yet in the [North American] showrooms right now. Too bad they insist on truncating the engine choices here. :mad: But the Mazda 323-based 1991+ Escort/Tracer was a pretty decent all around car. The Kia-supplied Festiva was a pretty good little car, too, believe it or not.

GM:

Like Ford, I think they have some great stuff available right now, and I was really impressed with the new Aveo and Cruze at the auto show, as well as the new Buick Regal GS (and that even had 3 pedals! :eek: ). The best car to wear a GM badge in the last 25 years though is probably the Nova/Prizm (which is a rebadged Corolla :) ).

Chrysler:

...we'll have to wait for Fiat to see what pans out, but other than the Challenger's mullet-factor, I do not see much else there to write home about. Yes, I know the Cummins engine is available in the Ram, but I do not need to move an apartment building around with me any time soon... or ever. :rolleyes: But as far as "good cars" to come from ChryCo, laugh if you want but the old K-cars were actually pretty simple, stout, solid, and reliable. EFI helped, so 1985ish+ any FWD car would be my pick. Boring, ugly (save for maybe the Daytona), but they were not an unreliable car all things considered.

HMC:

I think any 2000+ Hyundai/Kia product is a pretty well sorted car, even if they are a couple steps behind on engine technology, they seem to work well enough. HMC has rid the Kia lineup of any of the old models/platforms.
 
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