A3 2.0TDI 140 S LINE BLACK EDITION - Gearbox issues
A3 2.0TDI 140 S LINE BLACK EDITION - Gearbox issues
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jonriglar

Original Poster:

29 posts

260 months

Saturday 20th June 2009
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Hi all, just a quick post to ask if anyone has similar issues to that I have?

In march I bought a new '09 A3 2.0TDI 140. Its my third A3 of same engine size, though I realise the engine design itself has now changed to common rail. I'm having continuing issues with a noise from the gearbox. The engine itself is a quieter diesel from the one's I've bought in the past, so I appreciate other noises could be more obvious but when warm (I do about 40 miles each way to work each day) the gearbox 'buzzes' when in neutral..put it back in gear and it goes quiet.

I reported this to Audi in the first week. I'm now on gearbox number 3!! Audi said they could hear the problem on the first, and changed it. The second was admittedly quieter but still buzzing..the area tech manager said that was normal but they would change it if i insisted..which I did. The third is as noisy as the first, after only one journey.

Although the dealer is 'doing' things to try to help me, it's starting bug me...5 times they have the car, and still no true resolution. If its 'normal', why would they be willing to change each time (at a cost of £4K per gearbox as they have told me).

Anyone have similar experiences? I wont even mention the other issues (air conditioning compressor seems 'lumpy' when engine is cold, causing vibration through the car, plus part of the door leather insert trim falling apart!!)...oh i just did!

Any insights apprectiated..

Jon

Tame Technician

2,467 posts

235 months

Saturday 20th June 2009
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When you say it goes when you put it in gear, do you mean stationary with your foot still on the clutch?


Have they let you try another car of identical spec.??

A lone car of demonstrator the Audi centre may have for example. To see if it makes the same noises as your one.
If it does, and I suspect it will, they I'm afraid its not a fault, but a characteristic.

We had a customer try 7 different A4s one day because of a slight vibration at idle, like the engine stumbling, they all did it.

The whole engine drive line etc is quite loud on an A3, they have always been, much more so that A4 with exactly the same engines.

Steve081974

40 posts

210 months

Saturday 20th June 2009
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JON!! YES - ME!! I have the EXACT same issue, and my experiences are EXACTLY as yours... doesn't it make you want to AAAAAAAAARGH?!!

Only yesterday I had a nice long chat with a senior mechanic at my friendly local Audi centre - lovely chap, agreed it's annoying, but having already had a new gearbox, clutch and flywheel fitted (just one of each in my case mind you - I feel deprived..!) and having heard the same noise from a car belonging to their service manager, he was out of ideas as to what to suggest. He offered to raise a 'QC' - I believe that's a Quality Complaint - with Audi, and if your centre hasn't done that already please insist that they do! Apparently Audi only act when a certain number of customers have complained about the issue... which is nice of them I thought.

To answer TT, the transmission sounds fine when cold, or even after maybe 30 mins use. Only when the transmission is properly hot (after say an hour of driving) does the problem emerge, and it's extremely annoying. When idling with the clutch pedal up, it sounds like there's a small cement mixer churning away in the transmission - it's a completely unacceptable noise for a 22k car. The most similar sound I can suggest is a knackered thrust bearing. When you push the clutch pedal the sound persists for maybe 10 seconds, then runs down and stops. When you let the pedal up, it returns. Then here's the best bit - if you just nudge the gear lever towards any gear, it stops. That's without touching the clutch or engaging a gear - just holding the lever half and inch towards any gear and silence prevails. It's also possible to hear what I think is the same noise when coming to a halt or fiddling about at low speed, but that's a bit harder to pin down. The idling scenario above though is 100% evident and consistent, and drives me mad!

My car was delivered end-Feb, and since then it's been with the dealer for >3 weeks while they've tried various things to fix, all unsuccessful. A couple of weekends ago they arranged for me to drive an 'identical' car, and after 50 miles it made no such sound. I therefore concluded it was just my car with some mystery grumbling gremlin - then yesterday the above-mentioned super-tech guy discovered that although the car I drove had the same engine code, the gearbox code was different... so we're back to this being a 'feature' of this particular engine/gearbox combo and therefore apparently beyond fixing, because Audi don't give a monkey's as long as 'they all do that sir'.

I cannot adequately explain how irritating this 'feature' is - it's outrageous that Audi inflict such an obviously poorly engineered transmission on their customers and expect us to accept it. If I wanted a car that sounded like a cement mixer I'd have saved 21k and bought a 15 year old Fiesta.

As I say, my Audi centre, excepting a couple of communication wobbles, have been very good and try their best - but they seem to be stuck with a product that is fundamentally poorly engineered in this regard. Which is a great shame - in just about every other way I think it's a great car, ideal for my purposes... but every time I go any distance in it and this damned noise comes back, I just want to hit it with a hammer.

S.

Edited by Steve081974 on Saturday 20th June 19:50

jonriglar

Original Poster:

29 posts

260 months

Saturday 20th June 2009
quotequote all
Hi Steve

Thanks god for that, thought I was either possibly going mad, or being over picky...

My car does exactly what you say, and it really does bug you after a long-ish drive. The technical manager mentioned to me, after explaining it as a 'correct characteristic' that even his company Q5 makes this noise, at which point I was about to explode a say thats NOT something to be proud of, especially for those that have paid over 30K for that particular vehicle. I know I am frustrated with it all, but my view is that if it is a genuine characteristic with the new design box, then I should have saved myself 5k+ and accepted it as a characteristic of a noisy Golf TDi, or Seat TDi.

The dealer havent been able to provide me with an identical car to bench test. All I know is, that my older A3 140 TDI (2005), was very quiet and very reliable, and the 170 A3 I test drove at the dealer when deciding what to purchase did not make the noise..though I appreciate its most likely different gearbox ratios and perhaps the car wasnt as 'warm' on a shorter test drive.

Not quite sure how its going to end, apparently its a '3 strike and reject' policy by Audi UK on any individual components..therefore I am already on gearbox 3 (2 replacements) and they have one more chance to replace it and get it right. If its a design characteristic, possibly due to cost reduction, then they are likely to see many more returned as you would normally expect newer registration cars (of the same make/model) to be an improvement over old..unless of course the owners only go short distances all the time....

There are so many things I like about the A3, its styling, performance, and the brand image itself..but its a shame this is really putting me off as I feel like I am continually banging my head against a brick wall.



Steve081974

40 posts

210 months

Monday 22nd June 2009
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Hi Jon - we are of like mind!

I'm not sure where it's going either - I had a 140 TDi for two days as a demo before I ordered and I'm absolutely certain that car didn't make this noise, and I know the (then allegedly) 'identical' 140 TDi I drove a couple of weeks ago didn't make it either. Of course, now we know that's because both those cars had a different gearbox to our cars.

As I mentioned before, do insist your Audi centre makes a formal Quality Complaint to Audi. I'm told they act on receipt of five identical complaints, and we can only hope that there must be at least three other non-deaf vaguely mechanically aware owners out there who also have the nerve to expect their 20k+ to buy something that doesn't sound like farm machinery!

In the meantime I will certainly mention this discussion to my friendly Audi centre when I see them on Friday, and maybe TT can chip in with some insight or recommendation in his capacity as 'the mole'... wink

S.

Tame Technician

2,467 posts

235 months

Monday 22nd June 2009
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In my experience when you have a noise like that, when they all do it, by all I mean all the cars with that exact engine and gearbox combination, there is really nothing that can be done to fix it, because its not broken thats the noise the gearbox makes. It goes away after a few seconds with your foot on the clutch because the drive from the engine is then disengaged and the input shaft of the gearbox slows down and then stops.

A new gearbox of the same type will be the same, the only way to change it would be to out a different type of gearbox in there, but thats not something a manufacturer would do, the cars just aren't built in a way that allows major components to be interchanged like that.

The customer I spoke of before, who tried 7 different cars before he believed me when I said they all do (refuring to an engine vibration), actually backed the car, that is made the dealer buy it back. He then purchased one with a different engine that didnt have the characteristic (heavily discounted too i believe) Not sure what the process you would have to go through to achieve this is, as I only fix cars and dont get involved with any of that. But its always worth a call of letter to Audi UK customer services.

Sorry if this sounds like your being fobbed off, its just not the case. You do have to understand from a technical point of view, your cars aren't faulty, and thats why your dealer cant fix them. Though I thoroughly understand your point of £20k+ cars making annoying noises isnt on, and taking the issue up with Audi UK is the only way forward.

Steve081974

40 posts

210 months

Wednesday 24th June 2009
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Thanks TT - I understand your points from a mechanic/dealer perspective. I certainly won't be bothering to test seven different cars before I'm convinced it's just a fundamentally poor piece of engineering by Audi - I'm pretty much there already!

As I said before I don't really have a problem with the dealer - it's the fact that I'm stuck with a very irritating car which, due to a change about which I was not notified, performs significantly less satisfactorily than the car I test-drove that bugs me. I'm not sure of the legal position in this sort of scenario, but I could almost think it's misrepresentation to supply a demo car, allow the customer to order that car, change the mechanical spec for the worse, then expect him to drive around for four years with a cement mixer where the transmission should be.

Sadly as a company car I don't have the option of seeking a dealer buy-back or a frighteningly good deal on a swap, so it seems I have another three years and nine months of irritating Audi-powered motoring.

A very disappointing experience all round - I will probably try writing to Audi, but unless some sort of miracle descends from above I get the feeling this will be my last experience of Vorsprung Durch Technik - Audi's idea of 'progress through technology' and mine seem to be radically different!

S.

Edited by Steve081974 on Wednesday 24th June 17:38

wullie_t25

119 posts

211 months

Friday 26th June 2009
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Thanks for this thread my 02 Polo 1.9 TDi seems to have a very similar problem and yes its very annoying!!

Ive done the clutch and flywheel already and was going to try a re-con box but I think I will just wait and see if anything goes bang first!!

VAG need to get their act together, quality is really starting to slip on new models!!

jonriglar

Original Poster:

29 posts

260 months

Wednesday 1st July 2009
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Just thought I would give an update...

Gearbox number 3 (2nd exchange)...still buzzing when warm. Add to that my air conditioning system causes a vibration through the brake pedal when engine cold - stood idle at lights, air con in 'auto' and temperature set to a setpoint below outside temp gives a noticable judder that can be felt through the brake pedal.

Another series of phone calls to Audi local dealer. I got told now that there is no point exchanging the gearbox as 'its a characteristic of the car', and guess what, the air conditioning 'vibration' is also a 'characteristic of the car'!!! I am tempted to ask if the leather door trim issue (its come apart) is also a characteristic!

They are willing to take the car in again (number 6!) to check for fault codes recorded by the engine control unit, but nothing more. It can't be an characteristic in my view as it doesnt always do it - I'm told its the engine (being cold) lowering revs as the compressor runs up (though my logic would suggest the engine revs ought to increase to cope with the extra load?), but there is no noticable change to revs shown on counter, nor a engine note change. Plus, I hate to say it again, but my previous two A3s definately didnt do it.

Not quite what is going to happen next, the dealer is basically saying its the end of their support as they believe there is nothing left to do.

Steve081974

40 posts

210 months

Thursday 2nd July 2009
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Fun isn't it, this Audi ownership game?!

I've not noticed any air-con related nonsense from mine, though I must admit I'm a windows open kinda guy so rarely use it. I'll check it later and let you know if it does anything daft.

Re the gearbox, I am resigned to the fact that no amount of fiddling is going to improve what is clearly a fundamentally crap design - I intend to write to Audi directly to share my thoughts on that when I have the time.

The only thing I would say to pursue with your dealer is to ask them to confirm in writing that they have registered a Quality Complaint with Audi on your behalf - I'm advised by my dealer that's the only remaining avenue to pursue, and the more customers who report the same complaint via that process, the more likely (however unlikely that may be) that Audi will properly investigate.

Aside from that, the lesson is probably to look out for the new 1-series in 2011 which with luck will come with room for people this time... or just save 10 grand buy a year old Astra and go on several big fat holidays with the change next time around!

S.




Tame Technician

2,467 posts

235 months

Thursday 2nd July 2009
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It is a bit depressing to hear the trouble your having. I have a guy with a new TT that got a bit of clutch judder, he's the first person to complain about it on that model, I drove it a could feel what he meant, there was a judder there.

I tried 4 or 5 since and they all do it to. I got to call him tomorrow and say there's nothing we can do about that sir thats how they are. I'm, not looking forward to the call, I might get a service adviser to do it for me actually.

Its just people expectations are all different, he expect that an AUDI would be super smooth and refined and any level of judder or vibration was to him a fault. All the other TT customers havnt notice or think its acceptable for that type of car.


Regarding the A/C vibration. TO be sure its A/C related set the temps to LOW so the A/C is full on, then hit the ECON button and see if it goes away. The ECON button turns off the A/C compressor. I suspect what you can feel is the engine idles less evenly when its driving the compressor.

Sorry I cant be of any more help, just wanted to know its just as frustrating for those of us paid to fix cars, as it is for you guys who paid to own them.

Always write to the manufacture about these issues, customer power rules.

jonriglar

Original Poster:

29 posts

260 months

Tuesday 7th July 2009
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Thanks for that TameTechnician,

I have tried to do what you suggested (about turning the AC on/off) but since reading your post I have been unable to replicate the fault, which is even more frustrating! Asking a lame question time...would the ability to replicate the situation be dependent upon the outside ambient temp? From what I can tell, I need;

a) To have the engine stone cold (it occurs just after start up)
b) To have the air con target temperature set lower than outside temp
c) Make sure the air con is running at high fan speed
d) Be at idle...and now
e) Have a particular outside ambient temp...

With reference to the other issue (gearbox)..I still have a noticeable 'buzzing' when the car is warm (1hr drive). Finally, the dealer is going to give me an exact alternative car on loan for the day to compare. The local area technical manager (who says its a characteristic) I am sure is not hearing what I'm hearing so I appreciate that what he hears and says is correct might be correct, and in his view he is doing his best. I have a meeting with both him, and the dealer business manager once the dealer has received the replacement door trim panel and alternative car. So...if all the stars are aligned I might be able to make some progress, one way or another.

I have to say though that the dealer has not made any effort to do anything above the minimum - I've had to do all the chasing/organising, and there has been no offer of any sort of goodwill gesture. Unfortunately, this has pretty much made my mind up not to buy an Audi again, even assuming the issue is laid to rest in the near future to my satisfaction.







Steve081974

40 posts

210 months

Tuesday 7th July 2009
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Let us know how you get on with the matching car and follow-up meeting Jon - I'm afraid I wouldn't be surprised if the service guy IS hearing what you're hearing and it IS what Audi would call a 'characteristic' - I really am coming to the conclusion that they're just this bad!

I don't know how Audi can defend this situation - I test drove at length an 'identical' car before I placed my order, and between that point and delivery they changed the mechanical spec of the car for something worse, didn't tell me, and didn't give me the option to test the new spec and cancel (as I would have done).

It's rather like buying a new build house off plan, viewing the show home with four bedrooms and two en suites, then having bought 'one of those please', finding the keys you're given on completion day are to a three bedroom house with a bucket on the landing.

It completely undermines my enjoyment of the car whenever I travel any distance - if it wasn't a company car I'd ditch the damned thing. Unless miraculously some sort of resolution is forthcoming - which I very much doubt - I will certainly never buy another new Audi. The company clearly cannot be trusted to deliver what is ordered.

As you can tell, I'm totally over it now...! biggrin

S.

Tame Technician

2,467 posts

235 months

Tuesday 7th July 2009
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jonriglar said:
Thanks for that TameTechnician,

I have tried to do what you suggested (about turning the AC on/off) but since reading your post I have been unable to replicate the fault, which is even more frustrating! Asking a lame question time...would the ability to replicate the situation be dependent upon the outside ambient temp? From what I can tell, I need;

a) To have the engine stone cold (it occurs just after start up)
b) To have the air con target temperature set lower than outside temp
c) Make sure the air con is running at high fan speed
d) Be at idle...and now
e) Have a particular outside ambient temp...


Out side temperature shouldn't make any difference, it wont change what the A/C does significantly, the calculations by the A/C control module are more to do with the cabin temp than what its doing outside. Unless the outside air is cooler than the A/C air, then it sometimes switches off and bleed cold air from outside in, But I'll be impressed if that happens in July.

To test for possible A/C noises advise always set to LOW not just a lowish number, that way you are telling it what to do, rather than it doing what it thinks is best, which might not be what you want.

The fact that you have to have the fan running at high speed is making me think its something else, if it was the extra drag of the compressor, that wouldn't make much difference either.

I had a couple of those Black editions in this week, couldnt get the gearbox noise on either, but only did 15 min drives. Have had the same complaint about year ago on 1.9TDI A3.

You might think they are doing the minimum, but it sounds to me like the dealer are at least trying. Spare a thought for the poor sole, that spends six hours sweating putting a gearbox in and it still isnt any better. Its no fun I can tell you.

Hope you get it sorted.

jonriglar

Original Poster:

29 posts

260 months

Friday 17th July 2009
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Just a quick (but hopefully interesting update)...

Still waiting on Audi to get delivery of replacement door trim panel, so the car hasnt yet gone back into the dealer; however, through some digging around and calling in favours of friends in the industry I've managed to get some info from the Audi main database regarding complaints/known issues.

It would appear (and the person telling me this has no axe to grind) that there was a batch of A3 2.0TDI 140 Black Editions assembled in Portugal in the early months of 2009. A large proportion of these went into the Audi management network, for use as company cars for Audi personnel. The database shows a significant quantity of these have been rejected by Audi personnel within weeks of taking delivery, with a variety of concerns including noisy gearboxes, electrical faults and..trim quality issues. It will be difficult (I guess almost impossible) for me to verify the integrity of the information verbally given to me but it does suggest those people like myself with similar complaints on that particular type of car should persist in arguing the case with the main dealer...I know I intend to...

JKY

358 posts

223 months

Friday 17th July 2009
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I know someone with a new VW Scirocco that has the same noise issue and has been told by his VW dealer that it is a characteristic of the car and not a fault in manufacture - they all do it!!!
Seems that they really have a problem with this particular gearbox design. It may well be that there is a design fault in a strenghtened gear cluster and although not actually a faulty design it does have the unfortunate side effect of some extra gear noise!

Fat Audi 80

2,403 posts

282 months

Friday 17th July 2009
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JKY said:
I know someone with a new VW Scirocco that has the same noise issue and has been told by his VW dealer that it is a characteristic of the car and not a fault in manufacture - they all do it!!!
Seems that they really have a problem with this particular gearbox design. It may well be that there is a design fault in a strenghtened gear cluster and although not actually a faulty design it does have the unfortunate side effect of some extra gear noise!
Would anyone like to give us this gearbox code so that we can check / avoid in the future?

Cheers,

Steve.

warmfuzzies

4,378 posts

284 months

Friday 14th August 2009
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Wish me luck then, mine goes in for a new box next week...............

How long should I give it before the noise will start again do you reckon.....

K

Steve081974

40 posts

210 months

Monday 17th August 2009
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warmfuzzies said:
Wish me luck then, mine goes in for a new box next week...............

How long should I give it before the noise will start again do you reckon.....

K
Oh, about an hour... as soon as the gearbox is warm it'll be back! Sorry to be defeatist, but unless you get an interesting loan car to play with you're wasting your time - Audi clearly think we should be sufficiently honoured to be piloting their four rings about the place that the under-engineered rubbish they're nailed to shouldn't matter.

Disgusted (and resigned to another 42 months of farm machinery) of Winchester(!)



Edited by Steve081974 on Monday 17th August 20:13

warmfuzzies

4,378 posts

284 months

Tuesday 18th August 2009
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A5 tdi quattro with all the toys......