I had a weird clunking at certain speeds and though I know that's not exactly what you are reporting I will mention three things.
1. Tire tread sound. Some tires have tread that may start or wear to a vibrating sound like a pack of bees or something at certain speeds.
2. Gear oil empty. The passat front passenger side axle takes gear oil (not ATF). It's a thick oil. It's supposed to be lifetime but check that level. It's supposed to be right up to the bottom of the threads on the hole, in other words you fill it until it pours out. Wait 5 minutes for oil to sink in since it's so thick (manual says this) then check level again. (Note I don't recall if this applies to AWD, I have FWD.) PZ has a thread on differential fluid change here (link is to the internet archive version so that the pics are visible).
3. Tie rod loose. I know you said you checked them but if you are unfamiliar with that (like I was) there's really very little play to cause a problem. For example as you can see in my thread here the bad one only had an extra 1/16" of play.
The clunking went away for me after I disconnected the tie rod end to pull on it to check that for play on the inner rod and then put everything back together. I definitely need a new tie rod but the way I spun it or something I guess fixed it. Or adding the gear oil did it. I really have no idea. Just hoping it gets me to this summer so I can put in a new tie rod.
Soon after I got this car I changed all fluids. 3 gear cases, transmission, engine. They should be full, haven’t seen anything leaking. Only “clunk” I get is sometimes just before stopping when slowing down, assume transmission, another issue for another day. After I fix my Suburban, will check front end stuff again. Would rather do anything other than going after carrier bearing. PZ obviously has taken every single part on one of these apart, he makes it sound easy. Wish he wasn’t a couple thousand miles away. I like AWD advantages especially in Maine but just have more potential drivetrain issues to deal with. Will let you know.
S4 / RS4 (B5 Platform) Discussion - Drive Shaft Replacement Fun - Thought I would post a quick how to on drive shaft replacement as my search brought up little details. It looks as though my drive shaft was removed by the dealer early in it life according to recipts & was not installed with the...
I only had one pic of the driveshaft when it was out. There is a U-joint in the middle and it has CV joints at each end. The U-joint is pressed in, but the show that replaced mine made it replaceable with circlips cut into the joint. I did not take any pics of that.
Correct, the U-joint is at the center of the prop shaft with a CV at each end. It's a "staked" joint, pressed into place. You could grind down the stakes on each side and press is out, then press in a new one, but it has to be perfectly centered and I did not have the equipment for that.
Best pics are here:
Wouldn’t dare try to get new joint in perfect. If I go after it I would have friend of mine look at it, he is a machinist. Nothing to do up here, everything closed, would be good time to remove. Looking around I see several places that sell entire shafts, big $. Thanks
Just read link about center bearing. Could probably handle that, would just need to figure out a way to re-attach heat shield, and hope u-joint is OK. Decided that I don’t want to take a chance trying to get a new u-joint in perfect and re-stake. Like that article, but if I do job it will be solo.
My U-joint had rust streaks coming from the inside of one of the caps. I am sure it fell apart internally when I pulled the driveshaft apart to change the bearing. It was vibrating right after that.
I expect you can make a new heat shield from aluminum sheet and stick on reflective material.
Your vibration sounds a lot like mine. Wobble felt through the steering wheel, worst at 35 and 65 mph. Diagnosed as bad inner cv joints. Replacing the front axles next week with GSP’s from ECS tuning. $138 for the pair and 2 new axle bolts.
Ok guys, I just did the seafoam thing and changed out the oil. I do have suction at the oil cap, still a tiny leak, but here's the kicker; oil leaks out a LOT faster when the oil cap is off. What does that mean??? with it on I'm getting one drip about every 5 seconds, with it off it flows...
Anyone know of a cure for the rough idle while in drive? My POS Passat shakes very badly. I have had it in three different dealerships and not one could tell me anything besides "Oh, thats normal". Its not normal to not be able to see yourself in the mirror because the car is shakeing so bad...
I've seen this on many forums and it's always been a winner. Post up what you did to your car today. Add a picture or two that show what your did.
With that, I give you my addition, I polished my headlights.
I have a 99 VW passat I had to replace the Comfort Control Module. It was filled with water and well destroyed it along with the pigtails I was able to to get new pigtails and a new CCM and was able to connect all the wires to new pigtails except for one wire. I am hoping someone has the wiring...