03 jetta 1.8t question about issues...

My girlfriend owns an 03 1.8t that she purchased (certified used) almost exactly 1 year ago to the day... the car currently has 56K miles on it and the check engine light came on... $50 deductible on her warranty to diagnose a code for "catylitic converter" which was explained to us is "a dummy code that ALWAYS comes up... we checked it out and it's fine... btw, your synchromesh seems screwed up when we try to shift into third"... we agreed that third was strange and said we'd look into it soon. 1 week later and the check engine light returns - same deductible, different shop, same code, same explanation. We decided to get the synchromesh taken care of because it's "possible but not likely that this is the cause of the light" and it's under warranty so it should be free. Extended warranty company demands we take it to ONLY this SPECIFIC place or they will not cover it... fine... they decide to replace the transmission and let us know the car will be done on thursday...

5 days later (today), we are told that the clutch assembly needs to be replaced and will not be covered under warranty and that "in such poor condition it could not be returned to us until it had been taken care of"... it was explained that the "flywheel is basically gone, some pieces are missing, and it would completely shatter and fall apart before the winter was through so this could not be overlooked"

my question is simple... if this diagnosis of the clutch assembly is accurate, should we not have felt some slipping or experienced another such issue with the actual clutch long before this? Neither one of us has ever noticed a problem, nor had the first 2 places that test drove it. in fact, the only issue with the car other than the synchromesh was a rattling sound coming somewhere on the passenger side of the engine compartment that 3 places have given the technical diagnoses of "we don't know what it is, but the car drives fine so i wouldn't worry about it" *rolls eyes*... but anyways, yeah, clutch assembly... does it seem valid that 2 drivers and 2 previous test drives would not notice a "destroyed" clutch assembly through driving and now it's in such terrible shape all in a 3 week time period? or is this guy just trying to take us for a ride?

First to address you MIL (check engine light)

this is a concern to not take lightley this can cause more troubles.
plus there is no such thing as a dummy code. only dummy techs not looking for the right things.
If it is P1136, P0420 that have been pulled you could have several problems all fixable.
having just cleared the faults and it coming back means there is a problem with the engine managment system.
more likley that the Catalyst is bad and should be replaced.

Now for you Syncromesh first off you would not feel any slipping .
the newer flywheel are made of three parts to help stop harsh engagement there is the flywheel surface that the clutch is mated too, there is the damping center whitch has a heavy fluid and springs that has some movementin the center,then there is the wieghted side that is bolted to the crankshaft. that the other two pieces are hooked to it.

If your fly wheel is gone that means there is a problem with the flywheel dampener you have the right to see your parts and your car in the repair shop. one to verify that you are not being taken. even if you are not sure what your looking at.
If the flywheel dampener is blown then a whole flywheel clutch and preasure plate combo is the only way to fix it. do not let then tear down that trany for a possable internal concern as there is more than likely nothing wrong.

hope this help you .

Hey you said your car was (certified used) was it at a VW dealer or used car lot?
If you are VW certified call them up to see waht the can do for you.