02E DSG Dual Mass Flywheel for VW Jetta 1.9 TDI

This is a replacement dual mass flywheel for the 1.9L TDI cars running the 02E six-speed DSG dual-clutch gearbox. It carries OE part numbers 03G105266BE and 4150723090, and cross-references to DMF092. Fitment as listed by the manufacturer: 2005-2007 Volkswagen Jetta 1.9L TDI diesel and 2004-2006 Volkswagen Beetle 1.9L TDI diesel, automatic dual-clutch transmission. Match the OE number stamped on the flywheel you pull off before you order - the TDI cars ran more than one flywheel part number depending on build date and gearbox.

The dual mass flywheel sits between the crankshaft and the clutch pack and does two jobs at once: it stores rotating inertia like any flywheel, and it isolates the driveline from diesel torsional pulses through a spring pack sandwiched between a primary mass bolted to the crank and a secondary mass that drives the clutch. A 1.9 TDI puts sharp combustion spikes into that spring pack every power stroke, which is why these wear out long before the engine does.

Symptoms of a worn unit: a metallic rattle or growl at idle that changes or disappears when you take up the clutch, shudder and judder pulling away from a stop, gear rattle at low rpm under light load, and in bad cases a knock felt through the floor. On the bench the tell is rotational free play - grab the secondary mass and rock it against the primary. A healthy unit moves a controlled amount and springs back smoothly. A dead one clunks through slop, feels notchy, or does not spring back at all. Also look for grease slung out past the outer edge onto the bellhousing, heat blueing or hard scoring on the friction face, and chipped or worn teeth on the starter ring gear.

Replace it whenever the gearbox is out for a DSG clutch pack or mechatronic job - the labor to get back in here is the expensive part, and a tired flywheel will chew up a new clutch pack. Clean the crank flange and the flywheel mating face bone dry before it goes on, use new torque-to-yield flywheel bolts rather than reusing the old ones, and torque in the factory crossing sequence in stages. Support the weight while you start the bolts; hanging the unit off two threads is how flange faces get galled.