Audi Workshop Service and Repair Manuals

Fault-finding on power transmission - complaints regarding defects on the clutch and clutch mechanism   Note Checking hydraulic clutch mechanism → Chapter. Before carrying out any clutch repairs, always check out the customer complaint and the trace the cause of the fault. Investigate in each case whether the fault is caused by a defective clutch mechanism or by incorrect adjustment of the selector mechanism.

Complaint	Fault description	Fault rectification
Clutch pedal does not return to original position by itself	t  Air in hoses/pipes.	–  Bleed pipes/hoses; top up with brake fluid.
	t  Leak in pipes/hoses, master cylinder or slave cylinder.	–  Renew defective component, bleed pipes/hoses; top up with brake fluid.
	t  Clutch release bearing seized or sticking on guide sleeve.	–  Renew guide sleeve and clutch release bearing.
	t  Diaphragm spring of pressure plate is broken.	–  Renew pressure plate.

Complaint	Fault description	Fault rectification
Excessive force is necessary to operate clutch pedal.	t  Over-centre spring defective.	–  Renew over-centre spring.
	t  Increased clutch release pressure due to wear of clutch linings.	–  Inform customer that clutch release force normally increases due to wear of clutch linings. –  Renew clutch plate if the distance between clutch plate and rivets is less than 0.1 mm.
	t  Clutch release bearing seized or sticking on guide sleeve.	–  Renew defective components.
	t  Pressure plate with incorrect type of spring.	–  Allocate pressure plate according to → Electronic parts catalogue
	t  Mechanically defective pressure plate/clutch plate.	–  Renew defective components.
	t  Clutch plate does not move freely or is stuck on splines.	–  Check hub splines for damage (burrs). Renew clutch plate if necessary. –  Clean hub splines and input shaft to remove corrosion and remnants of grease and coat with grease for clutch plate splines -G 000 100-.Move clutch plate backwards and forwards and remove excess grease.

Complaint	Fault description	Fault rectification
Noises when operating the clutch	t  Release bearing defective, release bearing not guided correctly, contact surface worn.	–  Always renew release bearing if noisy. –  Renew guide sleeve if damaged.
	t  Contact surface (tips of diaphragm springs) of pressure plate defective (bent, broken). Contact point of release bearing off-centre.	–  Renew pressure plate. –  Check release bearing and guide sleeve, renew if necessary. –  Check position of release lever. –  Check dowel sleeves.
	t  Engine/gearbox off-centre.	–  Check dowel sleeves.
	t  Clutch plate installed wrong way around.	–  Install correctly.
	t  Wrong clutch plate installed.	–  Allocate clutch plate according to → Electronic parts catalogue.

Complaint	Fault description	Fault rectification
Grinding noises when engaging one of the forward gears or reverse gear; gear lever sticking, does not move freely; gears cannot be selected or clutch mechanism is without function	t  Air in system, clutch does not disengage fully.	–  Bleed system; check system, top up with brake fluid.
	t  Leak in pipes/hoses, master cylinder or slave cylinder.	–  Renew defective component, top up with brake fluid, bleed system.
	t  Travel of clutch pedal is restricted (carpet, floor mat under pedal) it is not possible to floor clutch pedal	–  Inform customer of the source of the fault.
	t  Pressure plate is distorted due to incorrect installation, clutch plate deformed due to incorrect handling.	–  Check components and renew if necessary, note position of centring pins. –  If there is still a grinding noise, check clutch plate splines on input shaft for freedom of movement, repair gearbox if necessary.
	t  Tips of diaphragm springs broken or bent (incorrect installation, release bearing off-centre).	–  Renew pressure plate. –  Check release bearing and guide sleeve, renew if necessary. –  Check dowel sleeves.
	t  Clutch plate too thick.	–  Allocate clutch plate according to → Electronic parts catalogue.
	t  Clutch lining sticking to flywheel (stored for a lengthy period of time, high humidity).	–  Lightly grind off friction surfaces for clutch linings or renew components if corrosion is excessive.
	t  Clutch plate does not move freely or is stuck on splines. Hub corroded, damaged during installation. Hub splines worn on one side.	–  Check hub splines for damage. Renew clutch plate if necessary. –  Remove traces of corrosion and grease from hub and shaft. Lightly coat shaft with grease for clutch plate splines -G 000 100-. –  Move clutch plate backwards and forwards and remove excess grease. –  Check position of dowel sleeves if hub splines are worn. –  Check release bearing, guide sleeve and pressure plate, renew if necessary.
	t  Pressure plate does not move away from flywheel far enough (wrong pressure plate installed).	–  Allocate pressure plate according to → Electronic parts catalogue
	t  Offset of engine/gearbox assembly above tolerance (dowel sleeves not fitted), support plate of clutch plate deformed.	–  Insert dowel sleeves before fitting gearbox. –  Check clutch plate and pressure plate for damage. Renew if necessary.
	t  Clutch linings have become loose due to excessive speed (shifting into lower gear at high speed). t  Clutch linings have come loose due to excessive clutch slip when driving off.	–  Renew clutch plate. Inform customer of the source of the fault.

Complaint	Fault description	Fault rectification
Load change shocks when accelerator is pressed briefly and when engine speed is reduced suddenly.	t  Engine/gearbox mountings too soft.	–  Inform customer of the source of the fault. Allocate mountings according to → Electronic parts catalogue, renew if necessary.
	t  Uneven engine running.	–  Check engine adjustments and rectify if necessary.
	t  Clutch plate is fitted with damper to prevent loose gear rattling noises.	–  Inform customer of the source of the fault.
	t  Engine/gearbox off-centre.	–  Check dowel sleeves and renew if necessary.

Complaint	Fault description	Fault rectification
Clutch slips, ineffective power transmission or vehicle does not move.	t  Wrong clutch plate or wrong pressure plate installed.	–  Allocate clutch plate and pressure plate according to → Electronic parts catalogue.
	t  Clutch plate worn, burnt; pressure plate overheated, scores; pressure plate deformed due to incorrect installation; contact pressure of pressure plate insufficient; poor driving habits; normal wear.	–  Renew clutch plate. –  Renew pressure plate. –  Inform customer of the source of the fault.
	t  Oil on clutch plate, pressure plate, flywheel. Oil seal of engine or gearbox defective. Grease on contact surfaces due to excessive grease on hub.	–  Renew clutch plate. –  Clean contact surfaces of pressure plate and flywheel. –  Renew oil seal, remove excessive grease from input shaft.
	t  Clutch plate installed wrong way around.	–  Install correctly, check clutch plate and renew if necessary.
	t  Flywheel recessed too far or excessive wear on clutch contact surface.	–  Allocate flywheel according to → Electronic parts catalogue. –  Check clutch plate and pressure plate. Renew if necessary.
	t  Leak in clutch slave cylinder.	–  Renew clutch slave cylinder.

Complaint	Fault description	Fault rectification
Grabbing clutch, engine jolts	t  Air in system.	–  Bleed system, check brake fluid level, check system for leaks. –  Renew defective component.
	t  Uneven engine running.	–  Check engine adjustments and rectify if necessary.
	t  Poor driving habits, rpm too low when driving off.	–  Inform customer of the source of the fault.
	t  Wrong clutch plate installed.	–  Allocate clutch plate according to → Electronic parts catalogue.
	t  Engine/gearbox mountings too soft, worn.	–  Check engine/gearbox mountings, if necessary allocate according to → Electronic parts catalogue.
	t  Oil on clutch lining, contact surface of pressure plate and flywheel (oil escapes from clutch housing).	–  Check oil seal for gearbox input shaft or crankshaft, renew if necessary. –  Renew clutch plate, clean pressure plate and flywheel.
	t  Clutch release bearing seized or sticking on guide sleeve (bearing applies pressure only on one side of diaphragm spring of pressure plate).	–  Renew clutch release bearing and guide sleeve. –  Check actuating components and mountings of actuating components.
	t  Contact surface of pressure plate moves away only on one side due to seized release bearing. t  Pressure plate housing deformed during installation. Contact surface of pressure plate moves away only on one side.	–  Check contact surface of clutch lining on flywheel, pressure plate and diaphragm spring, renew pressure plate if necessary. –  Renew clutch release bearing and guide sleeve.
	t  Excessive amount of grease applied to input shaft (traces of grease on clutch plate, pressure plate and flywheel).	–  Remove grease on pressure plate and flywheel, renew components if damaged (marks caused by clutch judder, traces of overheating, scores). –  Remove traces of grease from hub and shaft, apply a thin coat of grease for clutch plate splines -G 000 100- to shaft. –  Move clutch plate backwards and forwards and remove excess grease.

Complaint	Fault description	Fault rectification
Clacking sound can be heard when releasing clutch pedal	t  Mass of input shaft is accelerated due to sudden release of clutch pedal. Splines of meshing gears knock, the noise is increased on clutch plates with damper due to the damper moving to stop.	–  Inform customer of the source of the fault.

Complaint	Fault description	Fault rectification
Noises can be heard when engine is idling	t  Damper spring broken.	–  Renew clutch plate.
	t  Clutch plate installed without damper (rattling noises occur when engine is idling).	–  Allocate clutch plate according to → Electronic parts catalogue.
	t  Pressure plate deformed, broken, imbalance.	–  Renew pressure plate.
	t  Uneven engine running.	–  Check adjustment of engine and rectify if necessary.
	t  Offset of engine/gearbox assembly above tolerance (dowel sleeves not fitted).	–  Insert dowel sleeves before fitting gearbox.
	t  Intermediate plate contacts flywheel.	–  Engage intermediate plate at sealing flange and push onto dowel sleeves.