Clunk when transitioning to engine driving and engine braking (on/off throttle)

[Stuwey]

Mine is the 'fast road' insert. Can't see why you'd go any stiffer for something you drive all the time.

[kaanage]

OK, finally got another torque arm with a ployureathane bush (APR fast road) and had it installed. Again, the clunking has been reduced but it's still there .

While the car was up on the hoist we rechecked the driveline and the only thing noticable is a slight amount of backlash in the differential (nothing at all at the CV joints). My mechanic thought the amount of backlash was pretty normal but also that the Polo (VAG cars) may be tighter in this area than the cars he normally deals with.

So the cure would seem to be a new diff

[GoLfMan]

So the cure would seem to be a new diff

who cares, drive it until it pops, then chuck an LSD in there.

[kaanage]

If I can't get it warrantied , then that is EXACTLY what is going to happen
My only concern is that if it grenades badly enough, it may take out the rest of the gearbox internals and cases with it so I will be monitoring the noise level VERY carefully.

[Tim]

Have you guys ruled out the dual mass flywheel yet? Ive heard of quite a few being replaced on the diesel golfs.
There are a couple of videos on youtube showing the amount of play that exists in a failed one.

[kaanage]

The car was in neutral when we had it up on the hoist and checked the backlash - I may have to try it again, in gear

[kaanage]

I had the clunk diagnosed by Burwin VW and they said it was due to the passenger front hub bearing failing because a stretch nut there had been loosened and retightend when my cup kit was fitted and the nuts need to be replaced. I bought a bearing kit from them plus nuts for both sides to get my mechanic to fit them. Funnily enough, the clunk was reduced after the Burwin visit so I wonder if one of their mechanics tightened the hub nut when inspecting it.

My mechanic couldn't see any reason why the hub nut would have been loosened when the cup kit was installed (by someone else) but replaced the bearing on my instruction and now the clunk is gone. The original bearing seems OK (smooth and quiet) so I can use it as a spare when I kill one.

Even though Burwin wouldn't cover the bearing under warranty, I'm happy with them as their diagnosis seems to have been at least reasonably accurate (although I did have other work done to the front that could have removed the cause too) and I was only charged a small inspection fee. Unlike the the a$$holes that misdiagnosed my car who spun me the line about it being a CV joint and charged me heaps for the bs diagnosis . I'm going to confront them about this and give them a chance to respond before naming the morons.

[csimpson]

Very interesting, thanks for that. Any idea of the price for the bearings? I may replace mine.

Also swtiching to a single mass flywheel with the new clutch, so that may help...

[kaanage]

Here is what happened when I discussed the faulty diagnosis with the original dealer (Barloworld Moorabbin ).
http://www.vwwatercooled.org.au/foru...tml#post781337
Needless to say, I won't be going back there and don't recommend anyone else should, either

[csimpson]

Switching to my new clutch I have no clunking now.

HOWEVER, I think the ECS 14lbs flywheel or thrust bearing is ****ed (in the new kit), it's making a terrible noise at idle and below 2500RPM. I'm taking it back to Camden GTI tomorrow for them to diagnose and fix: if it's either the flywheel or the bearing, I'm going to be kicking up a huge fuss at ECS.

There's always something wrong...