I have 2005 2.0L TDI sport which has developed a noise that seems to be coming from the O/S/F. It only happens when the throttle is applied (not when coasting) and initially I also needed to be turning right. At low speed it sounded like a clicking noise, at higher speed it sounds like rubbing and grinding. As time has gone on it has got louder and now happens when driving on bumping or even undulating roads BUT ONLY when the throttle is applied.

My mechanic and I assumed it was the O/S/F outer CV joint which we replaced..to no avail. There is no play in any of the joints.  The only thing we did notice was that on startup the engine moves quite a bit in the bay although all the mounts seem ok.  

Has anyone had similar?  What was the solutioin?

Cheers!

I'd have guessed CV joint same as you.

Just randomly on the off chance it's not something fouling the wheel/tyre when cornering?

Checked all that, even replaced the wheel bearing, no change! grr!

Any luck with this over Christmas?

No change! taking it back to the garage next week for one last look then going to try a specialist..

It seems the noise is actually coming from the diff. I've been told its a replacement or recon diff job.. bugger. Anyone out there got any recommendations? apart from binning the car!

How much are we talking - have you had any quotes?

For a recon gearbox the cheapest I was quoted was 600 + vat and fitting.  I did contact a company from Northampton that can easily be found through google who recon various types and they kept telling me I'd probably need to get a new clutch and have the sixth gear fixed as it "often" fails but they wouldn't be able to tell me exactly what it needs until they have it off the car... suffice to say I didn't get a good feeling from them!