Replaces the worn dual mass flywheel behind the 02E DSG on 2005-2007 VW Jetta and 2004-2006 Beetle 1.9 TDI, OE 03G105266BE.
A 1.9 TDI Jetta or New Beetle with the DSG that rattles at idle, clunks when the engine shuts off, or buzzes through the floor just off idle is a common story once these cars pass high mileage, and the part usually responsible sits between the engine and the gearbox: the dual mass flywheel. This replacement carries OE numbers 03G105266BE and 4150723090 and cross-references to DMF092. It is listed for the 2005-2007 Volkswagen Jetta 1.9L TDI and the 2004-2006 Volkswagen Beetle 1.9L TDI with the 02E six-speed dual-clutch gearbox.
On a DSG car the flywheel is not a clutch surface. Volkswagen's Self-Study Program 308 traces the torque path: the crankshaft drives the dual mass flywheel, and splines on the flywheel engage the input hub of the double clutch, which carries torque to both wet clutches inside the gearbox. The flywheel is built from two masses with an arc-spring pack between them. The primary mass bolts to the crank; the secondary mass drives the gearbox. A diesel fires hard on every power stroke, and the springs soak up those pulses so they are not hammered straight into the clutches and gears. Over time the springs, their guides and the bearing between the two masses wear, the free play grows, and the pulses come through as noise and vibration.
Rule the gearbox out first. Scan the transmission module, and if the main complaint is shudder rather than noise, service the oil and run the clutch adaptation before condemning the flywheel; our DQ250 mechatronic and clutch guide covers how DSG clutch judder behaves, and the DSG overheating guide explains heat-related judder. With the gearbox removed, flywheel makers check two things: the free-play angle the secondary mass turns before it loads the springs, and how far it tilts or rocks against the primary mass. Limits are specific to each flywheel, so compare against the published figure rather than guessing. Grease thrown out past the edge or a dry, gritty feel when you rotate the secondary mass also points to a worn unit.
Listed fitment is the 2005-2007 Jetta 1.9L TDI and the 2004-2006 Beetle 1.9L TDI with the DSG dual-clutch gearbox. These TDI cars were fitted with more than one flywheel depending on build date and gearbox, and a manual-gearbox TDI flywheel is a different part. Read the OE number stamped on the flywheel you remove and match it to 03G105266BE, or send us your year and VIN before ordering. The 2.0L gasoline and later DSG cars use a different unit; see our DQ250 dual mass flywheel for the 2.0L. Everything else for these gearboxes is on the DSG collection page.
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Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
No. It is listed for the DSG dual-clutch versions of the 2005-2007 Jetta and 2004-2006 Beetle 1.9 TDI. Manual cars use a different flywheel with a clutch friction face.
Match the number on your old flywheel to OE 03G105266BE (also 4150723090, cross-reference DMF092). If yours has a different number, send us the year and VIN before ordering.
A rattle at idle in Park and a clunk at shutdown point toward the flywheel. Shudder while driving is more often oil, clutch adaptation or the clutch pack, so scan the gearbox and service the oil first.
New flywheel bolts every time. With the gearbox out, inspect the double clutch and its splines, and look for oil leaks at the rear main seal so they do not contaminate the new flywheel.
Running the DSG clutch adaptation after the gearbox has been removed and refitted is recommended, so the module relearns engagement. It needs the oil between 30 and 100 C.
