Transmission or Bevel Box failures

[2015S3]

Does anyone have or had a transmission problem or bevel box ( pre haldex) transmission related failure?

I am now hearing that these are creeping up as much as the Haldex failures.

My car is being diagnosed right now after replacing the haldex pump, haldex controller and the rear diff (with a low mileage) used unit.

Now we are looking into the trans???


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[kidkevin]

Had my mechatronics unit replaced at 31k after the car was experiencing jerking and rough shifts

[2015S3]

What is that? Did you have any 4 WD haldex issues when that happened?


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[kidkevin]

It's essentially the TCU control. It's the computerized part of the dual-clutch system.

I've had the haldex clutch pump replaced prior to the mechatronics replacement as well when the car was around 27k. I'm not entirely sure if the haldex failing was related to issues with mechatronics or not.

Are you experiencing any drivetrain issues currently?

[2015S3]

FWD burnouts in LC. Bad traction in rainy conditions again FwD traction control light illuminating. Bad traction around corners under heavy throttle.

Replaced the pump, haldex controller and the rear diff with another used low mileage unit and no changes.

They are trying to recode the AWD system today. We will see what happens

Stage 2 ECU, Stage 1 TCU Eurodyne


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[2015S3]

So you had haldex failure too?


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[kidkevin]

I did but the clutch pump replacement was able to fix it.

[2015S3]

So the trans problems were unrelated to the haldex issue? My car seems to shift fine


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[kidkevin]

Yup, my haldex and transmission problems were completely separate from one another

[Padriven]

Check out this thread. https://www.audizine.com/forum/showt...ghlight=Haldex

[2015S3]

Yes I have been on that thread for days replacing the pump, Haldex Control and rear diff.

[steveo987]

Does anyone have or had a transmission problem or bevel box ( pre haldex) transmission related failure?

I am now hearing that these are creeping up as much as the Haldex failures.

My car is being diagnosed right now after replacing the haldex pump, haldex controller and the rear diff (with a low mileage) used unit.

Now we are looking into the trans???


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I had a bevel box failure on my MK6 Golf R. There are specific symptoms that will tell you if it's an issue.
- A low "howl" at highway speeds coming from the drivetrain. It will progressively get louder as the bevel box gears begin to machine themselves to the point of complete failure.
- Slow turns will cause a feeling of almost binding up in the drivetrain. Again, it's the bevel box gears destroying themselves.
This was caused by the bevel box not being refilled to the correct level of fluid after being serviced. It took a week for the drivetrain to completely lock itself up (while the tech was test driving it around the block to diagnose the issue).

The only way to resolve it is to get a used bevel box assembly and replace the old one. NO bevel box assemblies available.

[2015S3]

I don't have any of those issues just excessive wheel spin during LC, in the rain and pulling out of a egress while turning the wheel.

[2015S3]

a tech is telling me they have been replacing transmissions on the S3/MK7R left and right yet I hear nothing about it. They are trying to recode the AWD system to see if that works.

[UNFUXWITHABLE]

My transmission is currently being replaced in my 2017 s3 due to jerking motion when taking off too fast , rpms rise drop then rise again when taking off too fast from dead stop, ordered new mechatronics unit and upon replacement they found metal shaving so they then decided to replace the whole transmission

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[UNFUXWITHABLE]

Btw only 11k miles and have never used launch control

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[sersanli]

Let me tell you my story on the bevel box failure...

I have a 2016 S3 (pre-facelift) and never had any issues on my car before. 1 year after driving it stock, I had APR stage 1 installed and I drove it for 9 months with stage 1, no track/no race. Before installing it, the APR dealer told me that it would not effect my warranty since it's undetectable. I didn't know the truth and I got it installed but I found out it was very detectable though. Let's come to the point.

Almost 1.5 months ago I was having a metal grinding noise coming from the back of the car. I took the car to the service and they replaced a coupling part #5Q0521307. At the same time, my car got flagged as out of warranty because of APR. Boom! Out of warranty, thanks to APR for claiming opposite, and thanks to APR for not replying my e-mails. Whatever, I took my car and there was something wrong. The noise was gone but my car was definitely a fwd car, doing fwd burnouts etc. Horrible...

I took the car to Audi service again and after keeping it for two weeks, they diagnosed that Haldex unit was broken and needed to be replaced for $6,000 - unfortunately its out of warranty as I said before. I decided to take the car to another private service and consult an old-school mechanic. Only in 20 minutes, yes 20 MINUTES! he told me that my bevel box was broken. A gear was slipping from a rod, I don't know if this is the right terminology for that but I can upload a video if I couldn't describe well. I told them that Audi service diagnosed my Haldex was broken and all that mechanic did was to "laugh" hysterically. They replaced the bevel box in an hour and suggested me to uninstall APR software. As they said, I uninstalled APR and I will not install it back again. APR probably don't care about customer satisfaction, it's horrible - I wrote them that their dealer claimed the ECU tune to be undetectable but as I experienced it's not and they don't take responsibility for that.

Bevel Box Failure: All I was told that the gears inside the bevel box were designed faulty. In previous cases they've tried welding the slipping gear and the rod but they got broken instantly. Replacing the gear/rod separately from the bevel box is not possible because of the wearing ratio of the other gears, only way is to change the whole bevel box. The torque you get with an APR tune may not effect DSG or Haldex but it definitely has a bad effect on your bevel box. I was told that it's one of the most fragile parts of these cars and to be careful specifically on it while tuning the car.

If any questions on this issue, feel free to ask!

[normcaldwell]

Let me tell you my story on the bevel box failure...

I have a 2016 S3 (pre-facelift) and never had any issues on my car before. 1 year after driving it stock, I had APR stage 1 installed and I drove it for 9 months with stage 1, no track/no race. Before installing it, the APR dealer told me that it would not effect my warranty since it's undetectable. I didn't know the truth and I got it installed but I found out it was very detectable though. Let's come to the point.

Almost 1.5 months ago I was having a metal grinding noise coming from the back of the car. I took the car to the service and they replaced a coupling part #5Q0521307. At the same time, my car got flagged as out of warranty because of APR. Boom! Out of warranty, thanks to APR for claiming opposite, and thanks to APR for not replying my e-mails. Whatever, I took my car and there was something wrong. The noise was gone but my car was definitely a fwd car, doing fwd burnouts etc. Horrible...

I took the car to Audi service again and after keeping it for two weeks, they diagnosed that Haldex unit was broken and needed to be replaced for $6,000 - unfortunately its out of warranty as I said before. I decided to take the car to another private service and consult an old-school mechanic. Only in 20 minutes, yes 20 MINUTES! he told me that my bevel box was broken. A gear was slipping from a rod, I don't know if this is the right terminology for that but I can upload a video if I couldn't describe well. I told them that Audi service diagnosed my Haldex was broken and all that mechanic did was to "laugh" hysterically. They replaced the bevel box in an hour and suggested me to uninstall APR software. As they said, I uninstalled APR and I will not install it back again. APR probably don't care about customer satisfaction, it's horrible - I wrote them that their dealer claimed the ECU tune to be undetectable but as I experienced it's not and they don't take responsibility for that.

Bevel Box Failure: All I was told that the gears inside the bevel box were designed faulty. In previous cases they've tried welding the slipping gear and the rod but they got broken instantly. Replacing the gear/rod separately from the bevel box is not possible because of the wearing ratio of the other gears, only way is to change the whole bevel box. The torque you get with an APR tune may not effect DSG or Haldex but it definitely has a bad effect on your bevel box. I was told that it's one of the most fragile parts of these cars and to be careful specifically on it while tuning the car.

If any questions on this issue, feel free to ask!

This is good info, thanks sersanli.
I'm sorry to hear about the misleading info your APR dealer gave you.
I'm also not surprised to read that the dealer truly had no clue as to what the real problem was; I'm glad you have a trustworthy mechanic to consult!

It was the rear bevel box, correct? There's one at each end of the driveline.

I've had the United Motorsport tunes, including their Haldex file, for 6,000 miles; including a few track days (track course; not 1/4 mile).
So far, so good.
I had fluids replaced for both bevel boxes, plus the Haldex, when I first got the car at 39k miles. Now at 45k miles.

Best on your bevel box replacement.

[sersanli]

This is good info, thanks sersanli.
I'm sorry to hear about the misleading info your APR dealer gave you.
I'm also not surprised to read that the dealer truly had no clue as to what the real problem was; I'm glad you have a trustworthy mechanic to consult!

It was the rear bevel box, correct? There's one at each end of the driveline.

I've had the United Motorsport tunes, including their Haldex file, for 6,000 miles; including a few track days (track course; not 1/4 mile).
So far, so good.
I had fluids replaced for both bevel boxes, plus the Haldex, when I first got the car at 39k miles. Now at 45k miles.

Best on your bevel box replacement.

Sorry I forgot to mention it was the front bevel box. I didn't specify because I thought the rear box was Haldex itself and didn't know there was rear bevel box besides the Haldex unit. I will upload the broken part's video when I got the time, you are going to be surprised when you see how a tiny misdesigned part can cause the failure of a whole bevel box.

Btw, they asked me if I tried the electronic emergency hand brake while driving fast and I said of course I didn't. They've seen people doing that and interestingly for several times this has been the reason their gear slipped in their bevel boxes.

Has anyone experienced anything with APR like I have? If yes, I would love to hear from you guys. I don't know what to do about it, I won't claim any compensation for the possible damages it caused but I just requested refund for the consequences of the misinformation their dealer caused...

[bakedcorn]

Curious, what’s the going price for this bevel box?


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[sersanli]

Around 2500 USD. I suggest you stay away from ECU tunes, especially APR where you can't find any customer service when in need...

[UNFUXWITHABLE]

Hey guys just got an update on my girl, the new transmission did not fix the issue unfortunately, the tech later got the idea to "unplug the rear diff" as they stated and the problem went away, no rpm rise and drop upon quick take off. So now they're waiting to get an approval for warranty on the rear diff . What else should I tell them to check ??? The front diff/ front bevel box ???

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[UNFUXWITHABLE]

What's going on everybody just got a new update SMH my dealer hit me up today and let me know that even after replacing the WHOLE rear differential, haldex and everything the problem still persists but again when they unplug the rear diff the problem goes away so now it seems like everybody there is just scratching their heads while looking at my car , I called our so call amazing wink wink Audi of America and the lady I spoke with whose name is pretty cool "Mona" told me that she would contact my dealer about the problems and talk about a buy back / trade in solution . Yeah well as nice as it all sounded in still waiting to hear back from them and when I call I get the run around. Very very frustrating experience. I think I'm pretty set on them replacing the whole car for a 2018 model s3 but I'm considering on squeezing out an RS3 lol for my troubles ;) let me know what you guys think

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[UNFUXWITHABLE]

I take back what I said , Head of my local dealership called and informed me that Audi is doing a complete and full refund for my 2017 s3 with just under 11k . I must say I am pretty surprised, I was expecting the run around for at least a month. I should be getting an options packet explaining my options on either a full refund or other ways audi can make this right and keep my loyal to the brand . So yeah guys hope this helps somebody

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[bakedcorn]

I take back what I said , Head of my local dealership called and informed me that Audi is doing a complete and full refund for my 2017 s3 with just under 11k . I must say I am pretty surprised, I was expecting the run around for at least a month. I should be getting an options packet explaining my options on either a full refund or other ways audi can make this right and keep my loyal to the brand . So yeah guys hope this helps somebody

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Wow color me impressed. Speak to your sales agent what they can do for you, they may actually go that extra mile or two to keep you in the family. Good stuff!



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[UNFUXWITHABLE]

Wow color me impressed. Speak to your sales agent what they can do for you, they may actually go that extra mile or two to keep you in the family. Good stuff!



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Do you think I should still stick with 3 series platform given all the common issues they have ? If anything I'd like to shoot for an rs3 lol for all of my time and frustration

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[bakedcorn]

Do you think I should still stick with 3 series platform given all the common issues they have ? If anything I'd like to shoot for an rs3 lol for all of my time and frustration

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TBH each model has their own issues including the RS3 / TTRS. I read something about fuel and oil mixing etc but don’t quote me - lol.
You are really thinking twice about take the monies and run man there’s no harm in that LMAO

The new Bullitt stangs are out I believe 🤪🤪


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[UNFUXWITHABLE]

TBH each model has their own issues including the RS3 / TTRS. I read something about fuel and oil mixing etc but don’t quote me - lol.
You are really thinking twice about take the monies and run man there’s no harm in that LMAO

The new Bullitt stangs are out I believe 🤪🤪


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Yeah man I have no idea , I thought about taking the money and buying something else but not a mustang lol, it took me 3 months to find the perfect one and I was so set on it being the car for me, I Bought almost every carbon fiber part I could find ( for a good deal ofcourse ) and a new set of Ray's g25 wheels that I haven't even put on lol. But I must say I would of been royally Ducked if I had any mods , first thing the service guy asked. And again I dont want to get a new one with the same issues, have you had any issues ??? I guess I'll wait till I get the options packet to make a final decision, I'll let you know. Thanks for your thoughts definitely appreciated

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[bakedcorn]

Yeah man I have no idea , I thought about taking the money and buying something else but not a mustang lol, it took me 3 months to find the perfect one and I was so set on it being the car for me, I Bought almost every carbon fiber part I could find ( for a good deal ofcourse ) and a new set of Ray's g25 wheels that I haven't even put on lol. But I must say I would of been royally Ducked if I had any mods , first thing the service guy asked. And again I dont want to get a new one with the same issues, have you had any issues ??? I guess I'll wait till I get the options packet to make a final decision, I'll let you know. Thanks for your thoughts definitely appreciated

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So far we haven’t experienced any Haldex issues but then again it’s simply a matter of if and when. Not every 3 series has this issue. Take your time with the options packet and good luck


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[UNFUXWITHABLE]

So far we haven’t experienced any Haldex issues but then again it’s simply a matter of if and when. Not every 3 series has this issue. Take your time with the options packet and good luck


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I'm glad to hear you aren't having any issues lol leaves some hope for me , I'll let you know how things go . Take care and thanks again. Have a good one

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[949]

any videos of this issue?

[UNFUXWITHABLE]

any videos of this issue?

Sorry couldn't find the video . But literally I let off brake and instantly apply half throttle rpms go up to about 3k drop to 1k and then go back up all within a sec or two and no trac light or anything and it's a very jerky feeling. Best I could do

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[JulienB8]

Just wanted to say thanks for this thread.
My 2015 Audi S3 went fwd all of a sudden. It is completely stock with 60K miles. luckily, I read this thread and I did not bring it to Audi (out of warranty anyway). Took it to experts in my area (USP Motorsports) and they confirmed it is bevel box not the Haldex that went bad.
I am getting a brand new replacement bevel box but I wanted to ask if there are any aftermarket upgrades and DIY preventive fixes? I see that sadly welding did not work.

What causes it to go bad? Does this issue arise only under heavy load? my car was stock and yes I beat on her (tracked it, backroads extreme spirited driving, etc.)but no tunes or other upgrades. I don't want to start the cycle of changing bevel boxes every few years. especially that while it is in the shop for bevel box I have decided to go with an IE stage 1 tune 93 high torque with some suspension upgrades. And I will start tracking her more regularly.

any thoughts on ways to avert this issue?

[mezgermischief]

My RS3 (2018, 21k ish miles, stock) has been plagued with issues mirroring those outlined here. Anyone else able to get audi to actually repair the car successfully? They keep giving it back to me saying it is fixed, only for things to get worse.

[o1turbo30v]

The transfer box/case/bevel box failures seem to fail much more frequently on tuned vehicles......

"Transfer Box Test

Make sure you are capable of doing this in a safe manor.
You are in control of your own safety. We are not liable for any damage or harm you may cause yourself, your workshop, other people, or your car. This test is only for automotive repair professional use only.

Lift the car so the front wheels are off the ground.
Get somebody or a camera to watch the propshaft.
Someone else to sit in the car, starts up the engine.
Apply foot brake, remove handbrake, put vehicle into drive gear.
Then very gently lift your foot off the brake so the front weeks start to turn.
If the prop shaft is stationary then the transfer box is faulty.
If the prop shaft rotates then you have a Haldex issue.

Transfer Box Failure generally only effects modified vehicles, almost every example has been a remapped car. Very common with Golf R, S3, RS3, TTS, TTRS etc. These transfer boxes are not designed to be robust, this is a really good youtube video showing how they fail inside https://www.youtube.com/watch?v=nt33-EgQ4gk"

Taken from the masters: https://www.haldexrepairs.co.uk/gene...-repair-guide/

[morris39]

The transfer box/case/bevel box failures seem to fail much more frequently on tuned vehicles......

"Transfer Box Test

Make sure you are capable of doing this in a safe manor.
You are in control of your own safety. We are not liable for any damage or harm you may cause yourself, your workshop, other people, or your car. This test is only for automotive repair professional use only.

Lift the car so the front wheels are off the ground.
Get somebody or a camera to watch the propshaft.
Someone else to sit in the car, starts up the engine.
Apply foot brake, remove handbrake, put vehicle into drive gear.
Then very gently lift your foot off the brake so the front weeks start to turn.
If the prop shaft is stationary then the transfer box is faulty.
If the prop shaft rotates then you have a Haldex issue.

Transfer Box Failure generally only effects modified vehicles, almost every example has been a remapped car. Very common with Golf R, S3, RS3, TTS, TTRS etc. These transfer boxes are not designed to be robust, this is a really good youtube video showing how they fail inside https://www.youtube.com/watch?v=nt33-EgQ4gk"

Taken from the masters: https://www.haldexrepairs.co.uk/gene...-repair-guide/

It is my impression (wrong?) that the propshaft rotates all the time but is only connected to the rear differential when AWD is required ie engage the clutches to the necessary degree. If that is correct how does the described test distinguish between Haldex and bevel box?

[o1turbo30v]

It is my impression (wrong?) that the propshaft rotates all the time but is only connected to the rear differential when AWD is required ie engage the clutches to the necessary degree. If that is correct how does the described test distinguish between Haldex and bevel box?

Because the propshaft is connected to the transfer case so if the transfer case is bad the propshaft won’t be turning, your right in that it will always be spinning so if it’s not in the scenario above the transfer case is bad.

[morris39]

Because the propshaft is connected to the transfer case so if the transfer case is bad the propshaft won’t be turning, your right in that it will always be spinning so if it’s not in the scenario above the transfer case is bad.

No bevel box in front so propshaft has no choice.
"The transfer box/case/bevel box failures seem to fail much more frequently on tuned vehicles......"
may be the only reliable statement if you go to their informercial. Sorry, misinformation is my hobby horse/

[Gberg888]

Interested to see what other news pops up in this. I have a tune on my engine but nothing on my trans. I have a 2016 S3.

[Thewheelm4n]

I had a bevel box failure on my MK6 Golf R. There are specific symptoms that will tell you if it's an issue.
- A low "howl" at highway speeds coming from the drivetrain. It will progressively get louder as the bevel box gears begin to machine themselves to the point of complete failure.
- Slow turns will cause a feeling of almost binding up in the drivetrain. Again, it's the bevel box gears destroying themselves.
This was caused by the bevel box not being refilled to the correct level of fluid after being serviced. It took a week for the drivetrain to completely lock itself up (while the tech was test driving it around the block to diagnose the issue).

The only way to resolve it is to get a used bevel box assembly and replace the old one. NO bevel box assemblies available.

Hey, did you ever happen to solve this? Used Bevel Box? I may have the same issue but my shop told me the rear diff is bad and causing the howling. I thought the car had a bad front axle, was "clicking/binding" sort of on slow turns. Seems Bevel Box could explain both issues, but I can't seem to find the right part #. 2015 Audi s3 here. Thanks!