Dead GT TDI DSG

[craigy]

My wife stopped the car, then got back in after a few minutes, ignition on as per normal turn to start position and nothing, no click or starter noises. I suspected dead battery even though it is 1 year old, so she attempted to jump start still nothing.
I got home late that night and went to where it was, battery measured 12.5V which is low but should be enough. Ignition lights don't even flicker when turned to start position.

Got the car home at 11 but couldn't look at the next day as I flew interstate, rang local dealer and they are booked solid and can't look at until next week.

Wife put battery on charge all day yesterday but no joy.

I fly home tonight and hopefully can check it out more thoroughly. I suspect the transmission lockout or some other start inhibitor. Any ideas?

[readerr0r]

My wife stopped the car, then got back in after a few minutes, ignition on as per normal turn to start position and nothing, no click or starter noises. I suspected dead battery even though it is 1 year old, so she attempted to jump start still nothing.
I got home late that night and went to where it was, battery measured 12.5V which is low but should be enough. Ignition lights don't even flicker when turned to start position.

Got the car home at 11 but couldn't look at the next day as I flew interstate, rang local dealer and they are booked solid and can't look at until next week.

Wife put battery on charge all day yesterday but no joy.

I fly home tonight and hopefully can check it out more thoroughly. I suspect the transmission lockout or some other start inhibitor. Any ideas?

Perhaps a blown fuse somewhere too?

[benough]

I'm going with battery.

I've had the cluster fuse fail in a MY11 Polo and all the other stuff still lights up.

[craigy]

Got to look at it this morning 0545 in the light. Swapped battery with my 2nd out of the 4WD. Still no go. Checked fuses and relays OK. Found starter motor under air filter, removed air filter box, applied 12v to starter solenoid 8A draw no turning of starter, 12v to starter is OK. Hooked voltmeter up to starter solenoid cable turned starter 12v is OK.

So my starter is dead. Will remove starter and check solenoid tonight.

[benough]

Nice sleuthing.

[craigy]

Starter motor brushes completely worn out at 80K. Trying to source new brushes, if not I will need a new starter.

[Transporter]

Too many short trips, perhaps?

In my T5 I do many short trips per day and many start ups, on almost every trip I arrive to customer's place and turn engine off, just to start up less than 5 minutes later to reverse on his/her driveway and at 105,000km the starter motor is still OK. I plan on keeping the van for some time, so it looks like the spare starter motor on stand by might be a good idea.

[The_Hawk]

Dead GT TDI DSG

Our 103 TDI multi is going strong after two years of lots of short trips (read school runs + sport etc) ... Here's hoping yours was just a bizarre failure rather than an endemic problem

[craigy]

Didn't do short trips for the first 60K when I drove it, now my wife has it most trips are short. The commutator looked good and I just spun it in the drill with some wet and dry to clean it up. I couldn't see any evidence that it caused the early wear.

I tried to buy a brush plate with new brushes unsuccessfully (VW sell the solenoid or the whole motor only, Tooley's sell only the whole motor). The auto electrician is looking for some brushes to suit which I will silver solder on. I am getting a new motor from the auto electrician for the same price as trade from Tooley's ($300 + GST).