Clutch/Flywheel Incompatibility Saga

[Cousinphil]

The clutch was chattering more and more. The only way I could get a smooth takeoff was to give it a lot of gas and let the clutch slip. The car has just over 100K so I figured it was probably the original clutch. I'm the third owner of this car but it had been well-maintained by Audi dealerships and, as far as I knew, everything was stock.

So I ordered a Valeo clutch from Rock Auto for a stock 2004. I decided to stick with the dual mass flywheel. I don't have a lift so I took it to a local garage to do the install.

Well, they dropped the transmission and removed the old clutch and then removed the flywheel and had it resurfaced. It was only then that they noticed that the flywheel and the new Valeo were incompatible. The original DMF had been replaced, at some point, with a single mass flywheel. Surprise, surprise. They called me up and gave me a choice: either a different clutch or a new DMF. We both did some searching and they came up with a Sachs dual mass flywheel. They could have it the next day. But the saga doesn't end here...

The new flywheel came but the bolts for the single mass didn't work for the dual mass. Another days delay. No big deal. Six bolts.

So I dropped in on them this morning to see how they were making out and they said they had the new bolts and would probably have it all back together within the hour. I requested the old clutch and flywheel and took them home with me just in case.

Well, a half an hour later I got a call from the garage and they were having problems. They couldn't get the new clutch to disengage. They wanted the old clutch and throwout bearing to compare with the new ones. So I drove back to Ellsworth again.

The fellow at the front desk had done some research and had learned that some years, 2004 being one of them, there had been incompatibility issues between certain pressure plates and certain disks and certain flywheels on the Audi 1.8T. He was confident that there would be a solution but it might entail buying some different parts. Unfortunately, the mechanic who is working on my car is going to be off for four days. So we are on hold until the middle of next week. Looks like I'm stuck driving the old Subaru. Sometimes it takes the patience of a piano tuner just to get through life.

[blitz2190]

if you even decide to return the parts I would recommend the valeo single mass kit, its smooth and has the same weight as the stock dual mass, I've had 70k trouble free miles on it so far.

https://www.fcpeuro.com/products/aud...FREHhgodpo0KVQ

[Cousinphil]

No incompatibility after all. It turned out to be some problem with the fork. The mechanic had to take the transmission down again, on his dime.

So I'm back on the road with a Valeo clutch and a Sachs dual mass flywheel.

And what a difference in the driving! The first thing I noticed was that the pedal is lighter. The second thing I noticed was that all the slop in the drivetrain has disappeared. The transitions between accelerating and trailing throttle were always a rough and tumble affair. Not anymore. Everything is silky smooth. Shifting is a dream.

And the most amazing thing: The car seems to have more low end torque. I can accelerate from a lower rpm now without the engine lugging. I can actually let the clutch out with the engine idling and move away smoothly. Wow! Never could do that before.

I've only driven about 25 miles with this new clutch/flywheel combination but I haven't noticed any decrease in power. The car is still plenty zippy.

The only drawback might be (might be) the loss of some sort of road feel. It's hard to describe. The car feels cushier now. More like an executive car and less like a sports car. I have a feeling I'm going to get used to it really fast.

[SJorge3442]

No incompatibility after all. It turned out to be some problem with the fork. The mechanic had to take the transmission down again, on his dime.

So I'm back on the road with a Valeo clutch and a Sachs dual mass flywheel.

And what a difference in the driving! The first thing I noticed was that the pedal is lighter. The second thing I noticed was that all the slop in the drivetrain has disappeared. The transitions between accelerating and trailing throttle were always a rough and tumble affair. Not anymore. Everything is silky smooth. Shifting is a dream.

And the most amazing thing: The car seems to have more low end torque. I can accelerate from a lower rpm now without the engine lugging. I can actually let the clutch out with the engine idling and move away smoothly. Wow! Never could do that before.

I've only driven about 25 miles with this new clutch/flywheel combination but I haven't noticed any decrease in power. The car is still plenty zippy.

The only drawback might be (might be) the loss of some sort of road feel. It's hard to describe. The car feels cushier now. More like an executive car and less like a sports car. I have a feeling I'm going to get used to it really fast.

Glad you got this sorted out! Don't get used to the soft pedal, that will go away in a few days. You can always change your over center spring for different pedal feel.

[Kevin C]

No incompatibility after all. It turned out to be some problem with the fork. The mechanic had to take the transmission down again, on his dime.

So I'm back on the road with a Valeo clutch and a Sachs dual mass flywheel.

And what a difference in the driving! The first thing I noticed was that the pedal is lighter. The second thing I noticed was that all the slop in the drivetrain has disappeared. The transitions between accelerating and trailing throttle were always a rough and tumble affair. Not anymore. Everything is silky smooth. Shifting is a dream.

And the most amazing thing: The car seems to have more low end torque. I can accelerate from a lower rpm now without the engine lugging. I can actually let the clutch out with the engine idling and move away smoothly. Wow! Never could do that before.

I've only driven about 25 miles with this new clutch/flywheel combination but I haven't noticed any decrease in power. The car is still plenty zippy.

The only drawback might be (might be) the loss of some sort of road feel. It's hard to describe. The car feels cushier now. More like an executive car and less like a sports car. I have a feeling I'm going to get used to it really fast.

Good to hear. FYI, your shop should have known that the flywheel bolts are a one time use part.