Problems after DMF installation

[D866]

Strange problem after a DMF installation into a 1.9 Tdi 2008 Caddy.
When the van gets hot a ticking noise starts and gets louder and louder. I suspect that the clutch/pressure plate is hitting something?
The flywheel was centred and torqued correctly, as was the pressure plate, the gear box is fitting in the dowels.
It’s strange as there is no vibration and when the van cools down after been off for a while the noise is gone until it heats up again!

Any ideas what I should check!

[Doc]

Is it possibly the dust plate that's touching the pressure plate?
These often get distorted and need some manipulation to prevent them rubbing.

[D866]

I thought that and I removed the smaller cover on the inside above the drivers side drive shaft to check but it made no difference.
What has me thrown is the fact it only does it when the car heats up which would make me think that something is has a tight clearance and then expands and starts rubbing as it gets louder as it gets hotter.

I think the only option is to take off the gearbox and see if there is any sign of rubbing in the bell housing.

It’s a Sachs four piece kit from Wexford so unless it’s a fake Chinese copy I’d say the DMF and clutch kit is genuine

[D866]

https://forums.tdiclub.com/index.php?th ... nt.424245/

Very similar problem to this so it may be the dust cover.

[theoldseacaptain]

One of my Touran's made exactly this noise when the DMF was failing - Had been previously owned by an older guy who drove it in 6th gear and engine on its knees most of the time!. The weakened springs were letting it touch one spot on the inside of the bell housing but only when air temperature was warm (over about 20) and engine was properly hot which made it an absolute nightmare to track down!

A quick trim with the dremel around the high spot before fitting the new DMF and no problems ever again. Went on to take it on long trips to South Europe, so 30+ degrees and very hot engine without issue.

[D866]

This makes perfect sense I will remove the gearbox and hopefully will find signs of rubbing. I'll update the tread with pictures for future reference when I'm finished.

[D866]

Just to clear this up, I took off the gearbox and ground off some of the bell housing where it looked like there was damage resulting in high spots.
All good upon refitment.

[PeeWee2k]

Good job! May i ask how hard it was to drop the gearbox? Need to the same in the near future

[D866]

No bother dropping it out. The second time I left the passenger side bottom arm and drop link in. And it still came out ok.
The tricky park is getting it back in. I used a fencing strainer to lift it back up as it’s hard to get a good grip on it.
Like most jobs it was done twice as fast taking it out the second time

[PeeWee2k]

Like most jobs it was done twice as fast taking it out the second time

really good point, so true! Thanks for the feedback!