NHTSA Complaint #10451066 — 2005 VOLKSWAGEN PASSAT

2.0L VW PASSAT TDI HAD A RATTLING, VIBRATING CHAIN NOISE FROM THE OIL PUMP BALANCE SHAFT MODULE IN THE OIL PAN. THE OIL PUMP CHAINS/SPROCKETS/TENSIONERS WERE WORN AND CAUSED NOTICEABLE VIBRATION AND RATTLING NOISE FOR THOUSANDS OF MILES; HOWEVER, IT WAS DIFFICULT TO DIAGNOSE. WE HAD THE ENTIRE OIL PUMP ASSEMBLY REPLACED BY A VW DEALERSHIP AT APPROXIMATELY 120,000 MILES WITH OEM GEAR DRIVEN PUMP WHICH INCLUDES THE BALANCE SHAFTS AND OIL PUMP. IT WAS A $3700 REPAIR TO EXCHANGE THE ORIGINAL OIL PUMP WITH THE GEAR DRIVEN PUMP. NOT A CHEAP SERVICE. THE SOUND BEFORE AND AFTER THE MODULE CHANGE WAS MUCH IMPROVED BECAUSE THE GEARS ARE QUIETER. THE REPLACEMENT GEAR DRIVEN OIL PUMP/BALANCE SHAFT ASSEMBLY USES A SIMILAR BALANCE SHAFT BUT WITH A DIFFERENT OIL PUMP AND GEAR DRIVE. THE GEAR DRIVE SMOOTHES OUT STRESS ON THE OIL PUMP HEX SHAFT SO RUNS MUCH BETTER. IN SUMMARY, I AM NOT HAPPY WITH HAVING TO DO SUCH AN EXPENSIVE REPAIR DUE TO A POOR DESIGN AT THE LOW MILEAGE OF 120,000 FOR A DIESEL THAT SHOULD LAST TO AT LEAST 400,000 MILES. THIS IS A RECURRING EXPENSIVE PROBLEM THAT SHOULD BE REIMBURSED BY VW. *TR