NHTSA Complaint #10359493 — 2004 VOLKSWAGEN JETTA

CATASTROPHIC DRIVE TRAIN FAILURE OF A VW JETTA TDI 5-SPEED. WHILE TRAVELING AT 65-70 MPH ON RELATIVELY FLAT TERRAIN ON A CLEAR ROADWAY IN 5TH GEAR WITH NO INPUT TO THE CLUTCH OR THE TRANSMISSION, OCCUPANTS FELT & HEARD A SINGLE, MUFFLED 'THUMP'. ORIGINATING DRIVE TRAIN FAILURE EVENT OCCURRED SPONTANEOUSLY AND COMPLETELY UNEXPECTEDLY. AFTER THE ANOMALY, A LOW METALLIC RATTLE WAS HEARD. ONCE CLEAR OF SURROUNDING TRAFFIC, IN TROUBLESHOOTING ATTEMPT THE DRIVER ENGAGED CLUTCH AND SHIFTED INTO NEUTRAL; IMMEDIATELY THE RATTLING BECAME MORE PRONOUNCED. FIFTH GEAR IMMEDIATELY REENGAGED AND NOISE ABATED. DRIVER NAVIGATED VEHICLE UNDER POWER TO RIGHT LANE & SUBSEQUENTLY EXITED EXPRESSWAY. UPON APPROACH TO SIDE STREET TRAFFIC LIGHT, THE CLUTCH WAS REENGAGED RESULTING IN A RENEWED RATTLING; TRANSMISSION SHIFTED INTO NEUTRAL. WHEN CLUTCH WAS LET OUT, THE CONSTANT RATTLING NOISE CONTINUED AS ENGINE IDLED. WITH SIGNAL CHANGE, CLUTCH REENGAGED & TRANSMISSION SHIFTED TO 1ST GEAR. CLUTCH SLOWLY, CAREFULLY RELEASED: NOTICEABLE NOISE INCREASE FOLLOWED BY SHORT SERIES OF LOUD, SHARP NOISES. VEHICLE LURCHED AND STALLED. TWO ATTEMPTS TO RESTART ENGINE FAILED; NO ENGINE RESPONSE. POLICE NOTIFIED & VEHICLE TOWED TO DEALER. SIGNIFICANT FLUID LEAKAGE NOTICED. SUBSEQUENTLY NOTIFIED BY VW DEALER THAT MAIN SHAFT OF TRANSMISSION CATASTROPHICALLY FAILED PRESSING FLYWHEEL INTO MOTOR DAMAGING CASING, BEARINGS & CRANKSHAFT LOBS RESULTING IN IMMEDIATE SEIZING OF THE DIESEL POWER PLANT. TOTAL REPLACEMENT OF TRANSMISSION AND ENGINE ASSEMBLY REQUIRED (EST ~$11K). THIS VEHICLE HAD ALL MAINTENANCE SERVICE PERFORMED REGULARLY AT 5K INTERVALS BY VW DEALER (DOCUMENTED) AND HAD RECENTLY HAD FULL 100K SERVICE INCLUDING TIMING BELT REPLACEMENT. NO NOTIFICATION/CONCERN FOR ADDITIONAL TRANSMISSION INSPECTION/SERVICE. CLUTCH RECENTLY SEEMED TO BE ENGAGING A WEE BIT FURTHER BUT NO BOTTOMING OF PEDAL OR CLUTCH SLIPPAGE. OWNER EXPECTED TO SCHEDULE CLUTCH INSPECTION/WORK DURING NEXT 5K SERVICE VISIT. *TR