Clunking noise solved!
09-04-2007, 05:03 PM
#1
AudiWorld Super User
Thread Starter
Clunking noise solved!
So I was in for my TB job today and mentioned the clunking noise to my new found indy tech.
He could replicate the noise easily in the parking lot. We got it up on the lift and looked around. He took a bar and moved the transmission up and down using the cross subframe member under the transmission as leverage. Once he moved the tranmission up, it made the clunk! I could hit the cross frame with my hand and it made the clunk noise again.
He determined it to be Audi's crappy decision of using crimp folds on the subframe cross member instead of welding the folds.
He welded the crimp folds in that cross member and no more clunk! We took it for a test drive and threw everything at it to make it clunk and it just wouldn't do it. Everything is solid.
Charged me an extra hour of labor for the welding and diagnostic, $65! Guess I saved $1335, as the cost of replacing the subframe from the dealer was $1400. Total cost for TB and welding labor, $326 with tax. Total with parts, $590.
This is the cross member:
<img src="http://www.1point8turbo.com/Random/subframe.jpg">
He could replicate the noise easily in the parking lot. We got it up on the lift and looked around. He took a bar and moved the transmission up and down using the cross subframe member under the transmission as leverage. Once he moved the tranmission up, it made the clunk! I could hit the cross frame with my hand and it made the clunk noise again.
He determined it to be Audi's crappy decision of using crimp folds on the subframe cross member instead of welding the folds.
He welded the crimp folds in that cross member and no more clunk! We took it for a test drive and threw everything at it to make it clunk and it just wouldn't do it. Everything is solid.
Charged me an extra hour of labor for the welding and diagnostic, $65! Guess I saved $1335, as the cost of replacing the subframe from the dealer was $1400. Total cost for TB and welding labor, $326 with tax. Total with parts, $590.
This is the cross member:
<img src="http://www.1point8turbo.com/Random/subframe.jpg">
09-05-2007, 12:59 AM
#5
AudiWorld Super User
Thread Starter
No problem...just hope I can help out others who have had this clunking noise and want to know an
exact cause instead of hearing the subframe needs to be replaced. Glad I had him look around, few spots of welding and we're good to go 
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09-05-2007, 11:55 AM
#9
Here?
<center><img src="http://pictureposter.audiworld.com/98458/subframe.jpg"></center><p>
Looks like a weld bead to me. This isn't the only location welded on the subframe, there SHOULD be symmetrically opposing welds also.
Looks like a weld bead to me. This isn't the only location welded on the subframe, there SHOULD be symmetrically opposing welds also.
09-05-2007, 01:04 PM
#10
AudiWorld Super User
Thread Starter
He welded right across the cross member that is running perpendicular to the
transmission. Both front and back of the cross section where the crimps are.
He had originally made some spot welds in some places that he thought that might have been causing the clunk but it didn't stop the clunk.
I'm on vacation right now but when I get back, I can take better pictures and point them out.
He had originally made some spot welds in some places that he thought that might have been causing the clunk but it didn't stop the clunk.
I'm on vacation right now but when I get back, I can take better pictures and point them out.