Audi Workshop Service and Repair Manuals

Removing and installing clutch (LuK version) Special tools and workshop equipment required

t  Counterhold tool -3067-

t  Centring mandrel -3190 A- t  Grease for clutch plate splines -G 000 100-

Removing –  Remove gearbox → Chapter „Removing and installing gearbox on vehicles with 1.8 ltr. TFSI engine“ or → Chapter „Removing and installing gearbox on vehicles with 2.0 ltr. FSI engine“. –  Attach counterhold tool -3067- before loosening bolts. To prevent the pressure plate from becoming distorted during removal (causes clutch grab when driving off), always adhere to the following procedure when unbolting the pressure plate: –  Working clockwise, loosen all six bolts consecutively in steps of 90° (1/4 turn) until the pressure plate is released. –  Take off pressure plate and clutch plate. Installing Installation is carried out in reverse sequence; note the following:   Note t  The dual-mass flywheel, pressure plate and clutch plate are matched together; components from another manufacturer must not be installed on the same vehicle. t  Always renew clutch plate and pressure plate together and select the correct parts according to engine code → Electronic parts catalogue. t  Checking position of adjuster ring on new pressure plate → Fig. t  If the clutch has burnt out, thoroughly clean the clutch housing, flywheel and parts of the engine facing the gearbox in order to reduce the smell of burnt linings. t  Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines -G 000 100- to the splines. Then move clutch plate backwards and forwards on input shaft until hub moves freely on shaft. It is important to remove excess grease. t  Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced. t  Pressure plate contact surface and clutch plate lining must make full contact with flywheel. Only then insert bolts. t  Check that dowel sleeves for centralising engine/gearbox are in the cylinder block; install if necessary. t  If the dowel sleeves are not fitted, this will lead to gear-change problems, clutch malfunction and in some cases gearbox noise (gears will make rattling noises).

Checking ends of diaphragm spring l  Wear up to half the thickness of the diaphragm spring -arrows- is permissible.

Checking spring connections and rivets –  Check spring connections -arrows A- for damage and make sure riveted joints -arrows B- are seated tightly. l  Renew pressure plate if spring connections are broken or badly bent, or if riveted joints are loose.

Checking position of adjustment mechanism (new SAC pressure plates only) l  The two edges -A- of the adjuster ring should be located between the two notches -arrows B-. l  If the adjuster ring is in a different position on a new pressure plate, the pressure plate and clutch plate must not be installed. l  The position of the adjuster ring can be outside the notches on used clutches.

Installation position of clutch plate: l  The marking „Getriebeseite“ (gearbox side) faces towards the gearbox

–  Use counterhold tool -3067-. –  Position pressure plate on centring pins. –  Use centring mandrel -3190 A- to centre clutch plate. To prevent the pressure plate from becoming distorted during installation (causes clutch grab when driving off), always adhere to the following procedure when installing the pressure plate: –  Screw in all 6 bolts evenly by hand until bolt heads make contact with pressure plate. –  Working clockwise, tighten all six bolts consecutively in steps of 90° (1/4 turn) until the housing makes contact with the flywheel. –  Working clockwise, tighten all 6 bolts to final torque consecutively. Tightening torque → Item –  Install gearbox → Chapter or → Chapter.