Dual Mass Flywheel Failure = Trans Suicide *Pics Inside*

[Drftlft]

Sooooooo my dads friend has a 2006 S4 in the exact color as mine and he asked me to drive the car a couple weeks ago saying it had a weird vibration. I hopped in the car started it up and HOLY S@$#!!!! i quickly shut it off and parked it in his warehouse and told him we have to pull the motor. After researching and reading that it sounded like his flywheel separated, me and "Getslideways" finally had the time Sunday to start working on the car. We got the front clip off and yesterday pulled the motor and trans as one unit, figuring it would be faster, and allow us to do some other maintenance items at the same time (seals, timing chain, etc...)

Surprisingly a lot easier to do then i thought it would be. As we got the motor on the ground we could see immediately it has some major cracks in the bell housing.....we pulled the transmission away from the motor and you could see the flywheel had been hitting the bell housing from the failure which cracked the housing nearly all the way around it. So now we have to find another transmission lol. I feel bad especially since he bought his right after i got my B7 and i was basically talking him into the car haha. Also hence why we pulled the motor for him.

Has anyone had any similar experiences and just welded up the cracks with any success? He has had a string of bad luck with this car since purchasing it, so if there is a way around telling him he needs a new trans, I am all ears haha

Pics for Clicks:

The Pull:







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The Carnage:

[skhan91]

holy! whats the mileage on that car?

[getslideways]

holy! whats the mileage on that car?

I'd have to double check with drftlft and the owner but i think its around 80k miles? I know its a good deal under 100k.

[Crispy Waffle]

This is my nightmare. Every time I drive my S4, I think any unusual noise is the engine exploding.

[Mr. Corey]

Dammm what year is this I didn't think the 06 B7's came with the dual mass flywheel as it was updated is this a 05.5 ...?

[getslideways]

Dammm what year is this I didn't think the 06 B7's came with the dual mass flywheel as it was updated is this a 05.5 ...?

It would be good to know if anyone can chime in for certain, as I believe there were some dimensional changes to accept the RS4 pressure plate when the B7 body change came along, but I thought it was still supposed to be a dual mass design (I am primarily one of those lowly B5 guys... so I am not 100% up to speed on all the various B6/B7 changes lol)

drftlft's is an 05.5 but the one shown here is I believe a 2006. My memory is crummy today lol

This is my nightmare. Every time I drive my S4, I think any unusual noise is the engine exploding.

A few beers, and a few friends make the motorpull less scary and more fun... well... when you aren't the one paying for the replacement parts haha

[c0ntract_thrill]

My dual mass went as well, the entire car vibrated. in my experience vibration usually is a sign to stop driving immediately, I towed my s4 to a shop and it was a good thing I did, dual mass had separated and because I stopped driving there was no damage to the housing.


I have seen this damage before but usually it is only B6's they revised the flywheel on the B7! Thats some bad luck!

[1.8t]

Damn, I should bring my s4 to you guys to change the guides loll.

btw, no nice way of telling him.. "you need a new trans" :P

[Jake@JHM]

There are people out there who think we are lying about dual mass failures and what they can do to your transmission.

This is unfortunate, but a good welder should be able to patch up that bell housing. We have repaired worse!

Time to upgrade! https://jhmotorsports.com/shop/catal...+combo&x=0&y=0

[Kambesama]

@Jake Why u scaring me and then tempting me

[kevinye77137]

@Jake Why u scaring me and then tempting me

Sales tactics. Its working on me

[WCCoffey]

I agree with Jake.

If it were mine I'd weld it up with out a thought... If it were a customer car I'd sell them a gear box... For what ever thats worth..

[Jake@JHM]

@Jake Why u scaring me and then tempting me

Sales tactics. Its working on me

It's more of an unfortunate truth that people don't want to believe. People do the same thing with the timing chain failures.

[wolverineottawa]

Been there I feel your pain! Same thing happened with my B6 S4. I posted the pics on another thread it was a disaster. I installed an aluminum flywheel stock disc and pressure plate and used trans of course.

[Juncura1]

There are people out there who think we are lying about dual mass failures and what they can do to your transmission.

This is unfortunate, but a good welder should be able to patch up that bell housing. We have repaired worse!

Time to upgrade! https://jhmotorsports.com/shop/catal...+combo&x=0&y=0

Just went through this with my 05' @ 60k. Ditched the dual mass and couldn't be happier. I've never been happy with any dual mass flywheel I've ever had any experience with. Those cracks are a lot less severe than I was expecting. A good welder should have no problem with those.

[SquiddyB6S4]

Welding okay, just make sure the flange is still true when done. If the mainshaft is off from the flywheel even a little, it could spell a huge problem down the road - over, and over, and over again.

Also, if you happen to get a replacement gearbox, I'd be happy to have that cracked one. I just want its guts. If somebody wanted to try welding the bellhousing I'd happily share the parts.

[Kambesama]

Sales tactics. Its working on me

It's more of an unfortunate truth that people don't want to believe. People do the same thing with the timing chain failures.

Definitely is working on me haha. Looking forward to a new clutch and flywheel from you guys Jake in the future. :)

[Jake@JHM]

Dammm what year is this I didn't think the 06 B7's came with the dual mass flywheel as it was updated is this a 05.5 ...?

The Updated B7 Flywheel is still a dual mass with the potential to fail. The updates they made to the flywheel were not to fix failures unfortunately. That is why we recommend upgrading to a single mass flywheel for all cars with a dual mass.

Definitely is working on me haha. Looking forward to a new clutch and flywheel from you guys Jake in the future. :)

Let me know if you have any questions or would like help placing your order!

[getslideways]

Drftleft and I dropped the trans off today to get welded up, fingers crossed all goes well...

With the money saved over hopefully getting a new trans, some extra goodies may be making their way onto the car

[vwaudi-tech]

I have a 23K mile 6spd trans and a new Audi DM and clutch with only 40 miles in it for sale.

[Tom in Seattle]

There are people out there who think we are lying about dual mass failures and what they can do to your transmission.

This is unfortunate, but a good welder should be able to patch up that bell housing. We have repaired worse!

Time to upgrade! https://jhmotorsports.com/shop/catal...+combo&x=0&y=0

Any deals on the Aluminum SMF and B7 RS4 clutch for 1.8T Audizine owners? I'll be fitting an 01E 6-spd soon. Thanks.

[1MoreSilverA4]

Happened to my '04.
Ended up replacing with a lower mileage unit from shokan, but heard a local b7 had luck welding his back together.





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[JimmyBones]

Happened to my '04.
Ended up replacing with a lower mileage unit from shokan, but heard a local b7 had luck welding his back together.





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I remember using that table. Thanks for sharing!

How has the car been treating you lately man? Did a lot of work on mine last year so I am making a good bit more power than the last time that I took you for a ride.

[wolverineottawa]

Here is what happen with mine. note the Trans was already repaired before I got the car the welds looked great but as you can see when the second flywheel let go it cracked along the welds, who knows if it was done right. Well it is now with the single mass alum flywheel and new/used trans. When you start getting that vibration get it looked as ASAP.

[SquiddyB6S4]

Wolverine, the transmission bellhousing (and other parts) are cast aluminum. Even "properly" welded, it still won't be strong, and the weld will represent a local weak spot. Interesting this is a second failure. I picked up a B7 dual mass flywheel with B7S4/RS4 clutch and pressure plate; I guess your previous replacement flywheel was also a B6S4 flywheel, or it shouldn't have failed.

By chance, what happened to your old transmission? Tell me you didn't junk it!

[wolverineottawa]

Wolverine, the transmission bellhousing (and other parts) are cast aluminum. Even "properly" welded, it still won't be strong, and the weld will represent a local weak spot. Interesting this is a second failure. I picked up a B7 dual mass flywheel with B7S4/RS4 clutch and pressure plate; I guess your previous replacement flywheel was also a B6S4 flywheel, or it shouldn't have failed.

By chance, what happened to your old transmission? Tell me you didn't junk it!

Not sure what happened to be honest. I was involved with a friend of mine (at the time) in a shop. I know the old trans was in the shop at the time. Nothing good to say so I wont air out dirty laundry here. Basically its gone.

[SquiddyB6S4]

Not sure what happened to be honest. I was involved with a friend of mine (at the time) in a shop. I know the old trans was in the shop at the time. Nothing good to say so I wont air out dirty laundry here. Basically its gone.

[wolverineottawa]

Trust me I am thrilled