We just experienced a expensive ($4500) problem with the VW VR6 which is the basic 3.2 Audi.

Actually the problem was relatively minor but became major because of the engineering. A sprocket that part of the camshaft drive assembly was worn to the point that it was almost completely rounded. This caused the timing chain to jump. Fortunately it did not jump enough to cause the valves to hit the pistons.

The problem started at 52,000 miles. I had it repaired at 55,000 miles.

The sprocket apparently was not properly hardened on a few of the VR-6 engines.

I have a more complete report with photo and invoice at: http://www.reesphotos.com/VW/

Although the web page doesn't solve the problem or get the fiasco paid for it does seem to relieve a lot of the stress this incident has caused.

John Rees<ul><li><a href="http://www.reesphotos.com/VW/">http://www.reesphotos.com/VW/</a</li></ul>

The reason for the warranty is to cover manufacturer defects for some reasonable amount of time. I guess a reasonable amount of time is not long enough for this car. Apparently, it should have had a 100k mile drive train warranty.

It does not look like a design or engineering defect, more like a supplier quality issue or overly aggressive penny pinching purchasing department at VAG.

I wonder how many of these defective timing gears are out there?

The dealer service departments (for many manufacturers, including Mercedes) and service advisers almost always act like these recurring problems do not exist. This way do do not face the problem, until there are so many failures, that they are forced to recall the product (like have 10 failed cars a day).

In the 2002, 2003, 2004 Mercedes C32, there was a very common issue with both the intercooler leaking &amp; the coolant pump failure after about 40k miles. The dealer service advisor always denies that the problem exists or has ever existed until it they are forced to believe it by extremely obvious evidence.