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Discussion Starter · #1 ·
162K miles on the original clutch, no slipping, no chatter, smooth engagement. GIAC-X since ~40k. Again, no issues with driveability and I've never been a clutch dragger like some folks I've ridden with, LOL. Recently I've noted that as I release the clutch pedal while engaging the next gear, I can hear a metal-on-metal click or tap as the clutch engages. Really can only hear it when the windows are down, so its definitely coming from the tranny/flywheel area. Seems most notable in low gears, like 1-3. Could this be my DMF has failed and no "spring" left so it clicks instead of damping the energy as the clutch is released when engaging the next gear? Just curious if it might be time to start thinking about a new clutch/flywheel.
 

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Does it still make the noise when you release the clutch with the engine off?
 

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Discussion Starter · #3 ·
It's not the pedal....its definitely the sound of two plates in the clutch coming together. Its more like a metal "clack" kind of sound than a "click" I guess. It seems like there's no "give" in anything and that's what's causing the sound. I also wonder if this means my dual-mass flywheel is seized. The clutch itself is fine, holds great under max acceleration in 5th gear and engages without chatter. It just makes this kind of "clack" sound for a moment right as the drive train hooks up when the clutch is let out. I can prevent the noise by slipping the clutch slightly, but I only did that as a test. I'm pretty good at knowing exactly where the bite point is and being able to hit it accurately. Its only when I'm more abrupt about releasing the clutch and reapplying the throttle that I notice this. I've read that dual mass flywheels are known to fail fairly regularly and are a "wear" item so I'm thinking this is the likely cause of the noise and was just hoping someone more knowledgeable or experienced could confirm.
 

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Discussion Starter · #5 ·
I had the car to my local Euro master mechanic (and a former instructor at Audi university in the UK) several months ago for a myriad of small issues, and he said all my mounts looked good. Actually, I specifically asked about them since I know they don't last forever.

I'm 99% convinced its that my DMF is basically seized and now just acting like a SMF.
 

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Thread title makes it sound like a transmission (wear) issue. Desired gear is already engaged before releasing the clutch.

Topic for another thread, but my '04 AWM 1.8T's transmission makes the "clack" sound when engaging 2nd or 3rd gear, not as loud in 4th. I'm on the lookout for another 5 speed - sometimes difficult to engage 2nd gear.
 
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