Engine Mounts

Pompeydave said:
The clonk occurs when I move the gearstick. When the clutch pedal is dipped or raised there's no noise at all...
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Worn synchro rings is your problem then, I suspect. When the synchro ring is pushed towards the cog, the conical clutching system is no longer strong enough, meaning that rotational speed matching doesn't take place fast enough. Then, when the synchro sleeve slides over the cog's dog teeth, the dog teeth suddenly take up the difference in rotational speed, causing a slight metallic clonk.

When you try to engage 1st gear as you roll to a stop (in preparation for setting off again), do you have some sometimes 'massage' the gear stick into 1st gear?

Cheers,

Tom
 
No, but 3rd gear crunches as if synchro is on its way out if its engaged too quickly. The car has done 187k so am I looking at a recon box? If so I would rather just go for a good used 90 engine and box if I can find one...
 
Pompeydave said:
No, but 3rd gear crunches as if synchro is on its way out if its engaged too quickly. The car has done 187k so am I looking at a recon box? If so I would rather just go for a good used 90 engine and box if I can find one...
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Join the club
Dan and mine are also a little recalcitrant.

J
 
The 3rd gear synchro is generally the one that wears fastest on the A2, and other 02J 'boxes.
 
Ok, the only thing I'm doubtful on that diagnosis is that the clonking sound is more akin to something you'd hear when a suspension part is worn. Wouldn't a worn gearbox sound more metallic in nature rather than a dull 'clonk'? Having said that 3rd gear synchro is definitely on it's way out. Is there anything else that could cause that sound? Gearchange cables?
 
Pompeydave said:
Ok, the only thing I'm doubtful on that diagnosis is that the clonking sound is more akin to something you'd hear when a suspension part is worn. Wouldn't a worn gearbox sound more metallic in nature rather than a dull 'clonk'? Having said that 3rd gear synchro is definitely on it's way out. Is there anything else that could cause that sound? Gearchange cables?
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Yes, my thoughts too.

The synchro noise is more of a crunch.

When changing gear, the weight of the car shifts as you dip the clutch and so the noise could be suspension related.
The only clunk from the gearbox would be backlash (not common on these because there are no propshaft joints), or UJ clunks (also not that common)
The exception would be a small clunk that could come from a worn gear selector mechanism. Does it clunk when changing gear when stationary? That would help narrow the cause.

Steve B
 
No, it only does it when the car is on the move, which makes me think it's something to do with the engine/gearbox moving around or stressing a suspension part as I'm changing gear. Having said that, I can't hear the clonk when changing up or down between 3rd, 4th or 5th, but that may be due to road and wind noise drowning it out at higher speeds...
 
Quick update- I found an as new main engine mount (8Z0 199 212 C) for £29 inc p&p from German Ebay, and a brand new gearbox mount (8Z0 199 543) for £122 inc p&p from a German parts site for the 1.4tdi AMF engine. Just waiting for them both to turn up. If they're the bargain I think they are, I'll be well pleased with the prices.

By the way, apologies Timmus for hijacking your thread, I couldn't see a better one to make the initial enquiry in...
 
Pompeydave said:
By the way, apologies Timmus for hijacking your thread, I couldn't see a better one to make the initial enquiry in...
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That's OK... I'm not sure I'd consider this a hijack. In many ways, it's best to keep as much related information in one thread, rather than having engine mount threads for every member who considers changing them.

I'm glad you've found some good deals. Hopefully they'll solve your issues.

Tom
 
Hi there
Coming back to the engine mount topic...
I got a chance to change my torque arm 2 weeks ago and I must say : It does improve a bit the knocking effect I had with on-load /off-load engine.
But it still doesn't feel as smooth as in some other cars I get to drive now and then.
Since the part is very expensive ( from audi dealer...now I know why you guys call them stealer instead ) I 'm not so sure if it was worth changing it in my case. The old part had some play between the rubber and metal but didn't look so badly worn out.
So far I'm trying to get rid of strong engine noise and vibration, especially under load. And there is no improvement in that field.
I'm considering to change the 2 other mounts but they are so damn expensive through my stealer...
So Dave, I'm looking forward to know if changing your engine mounts will really help to sort your shaking issue before I decide to go the same way !
 
Hi jemsom, well the used but as new engine mount arrived from Germany this morning. I'll update the results in this thread. I'm now just waiting for the gearbox mount to arrive, again from Germany. Anyone know if the main mount can be fitted DIY? Doesn't look anything too technical, I'm guessing it's a just case of supporting the engine from underneath while the mounts are changed over?
 
The main mount replacement is a DIY job. Use a jack with a piece of wood between the sump and the jack, the piece of wood being as large as possible to spread the load. Don't do it without the piece of wood. You will also need a suitable torque wrench.

RAB
 
No, because I have a different mount and model. Buy a copy of Elsawin from Ebay. Very cheap and very useful.

RAB
 
Update. Tried to fit the good used engine mount. Not a chance sadly. The mount cap came off easily enough and the side and front bolts of the mounting itself were no problem. The rear bolt had a load of corrosion around it and just would not shift. It's positioned in such a way that you can't easily get a socket and extension bar on it. The bar fouls the engine bay lip that has the rubber strip pushed on it all the way around the bay. If you try to lean the bar forwards the socket just comes off. Didn't want to round it off so I looked at the existing mount with the cover off- it's actually in very good condition with no flaking or distortion of the rubber. It doesn't look all that old so it might have been replaced by the previous owner at some point.

The gearbox side mount is still en-route from Germany, but I'm starting to think that the shaking I am getting, particularly under load, is transmission related. Is it possible that something in the box is so worn as to cause this shake? It's covered 187k after all....
 
regarding the 120Nm + x degrees and not replacing bolts: you are playing with fire, as the bolts are stretched deliberately by the +90 degrees or whatever. There are several cases of worn bolts shearing on the German forum, so I would personally follow the recommendations in this case and replace the bolts every time.

I'm now trying to track down an interesting vibration under heavy load (and only heavy) at 80-100km/h. Might be anything, but at 146k kms, I think the mounts are going to be the next things replaced.

- Bret
 
Quick update. The new nearside engine mount has arrived from Germany. It's exactly the same stiffness as the existing one, so it looks as if I didn't need it. ******. I think I have a worn out box at 187k. Oh well, if I can get a decent JDD box I'll fit the new mounting to it and renew the clutch at the same time...
 
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