Initial complaints: Reverse on an even road, a “Ka Ka” sound was heard from the lower section of the engine bay
Cause: The sound may come from the end of the transmission or from the dual-mass flywheel
Solution: Readjusting the dual-mass flywheel may address this issue.
- To confirm the symptom: close all windows, reverse on even road and the noise comes from the transmission (noise evaluation must be done in the vehicle with all windows closed)
- Lift the vehicle, video records the flywheel in motion when the gear is in P and R as reference points for later steps.
- Note that you may need to use VW tool T40169 / T40170
- Step 1:
- 1. Remove 3 bolts, and keep the bolt in its original position (Distance the flywheel a little from the engine to ensure these two are not in contact.)
- 2. 2NM to pre-tighten all 3 bolts.
- 3. 60NM to tighten all 3 bolts.
- Test the vehicle. If the noise persists, follow step 2
- Step 2:
- 4. Remove 3 bolts again, and rotate them for 60 degrees
- 5. 2NM to pre-tighten all 3 bolts.
- 6. 60NM to tighten all 3 bolts.
- Test the vehicle. If the noise persists, proceed with step 2 again and keep rotating the bolts until they have been rotated for 240 degrees.
If the issue persists and the sound is indeed from the flywheel, consider replacing the flywheel.