Engine Belts And Pulleys problems of the 2004 Volkswagen Jetta

The contact owns a 2004 Volkswagen Jetta. While driving approximately 65 mph, the contact stated that the vehicle stalled without warning. The contact did not inform the dealer or manufacturer of the failure. The vehicle was taken to a private mechanic who inspected the vehicle and advised the contact that the timing belt was fractured and would need to be replaced. Also, the tensioner and engine may have been damaged and the contact was awaiting the results. The current and failure mileage was approximately 94,000.

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.