Noise coming from DCT when shifting up through gears

[JustRubes]

Hi guys,

I'm not sure how long this has been going on for but I've recently notice a nasty sound coming from my DCT, most prominent when shifting from 4-5 in auto.

I can consistently get the noise to come just by cruising in auto and letting it go from 4-5. I think I'm hearing it in other gears but much softer.

These are not my videos but they sound very similar, maybe the videos are a bit louder.

I lifted it and ran through the gears while the car was in the air and you could still hear the sound. The sound seems to be coming from the back of the gearbox OR the flex plate.

Couldn't see any obvious leak but I'll be looking deeper this weekend and doing a service on the DCT.

It was running GTS map and GTS gearbox flash but I've returned it all to stock and the noise is still there.

I'm hoping it may just need a fluid change as it is on 85k mi.

No codes, it drive and shifts smoothly as expected, just this noise which now that I've noticed it I just cannot stop hearing it!

Any advice greatly appreciated!

[FrankMstein]

Was the fluid changed recently?

[JustRubes]

No and no history of it ever being done either. Plan to get it done this weekend.

Really hoping it’s nothing serious, got a road trip coming up in two weeks so if it turns out I need a replacement box I might be in trouble!

[JustRubes]

Did dct service, fluid, filters, oil pan.
Sadly the sound is still there...

Fluid was very watery and dark, but couldn't see any glitter/metal fragments. filters looked clean of metal as well.

[JustRubes]

I'm now also getting the same noise if I'm driving in manual and hold onto 4th gear. It'll make the clunk/chirp, and then won't do it when entering 5th gear.

[FrankMstein]

Will try this today.

[JustRubes]

The sound is killing me! Every shift from 4-5 is making a pretty unpleasant sound

[TopJimmy]

Rubes, what you type hurts to read. If the trans is making noises in a certain gear or between two then you may have a bad gear, bearing or synchro/brake. I would be pulling the trans and rebuilding, or swapping in another.

Too bad you’re on the other side of The Pond as I have a good spare DCT and E-diff wrapped up in my garage.

[JustRubes]

I thought so I'm guessing my best/cheapest option is to buy a used gearbox and fit it.

Do you know if the car is safe to drive until that gear fails entirely?

I would guess it means more than one gear is failing because:
-gear 4-5 crunches everytime in auto
-while driving in 4th manually, it will make the crunch then wont make it when switching from 4-5
-sometimes when shifting manually, it will make the sound down shifting 6-5

[TopJimmy]

The DCT has a filter so maybe all the garbage/metal went there. I wouldn’t push my luck…

[JustRubes]

I did dct service including filters and cut the filters open. No debris to speak of, no glitter.

The fluid that came out though was black and thin as water.

[tooch]

curious how many miles you have