Audi Workshop Service and Repair Manuals

Removing and installing dual clutch

Special tools and workshop equipment required

t	Hook -10 - 222 A /2-

t	Workshop hoist -VAS 6100-

t	Extractor tool -T20143/2-

t	Puller for ATF supply unit -T40123 A-

t	Centring tool -T40199-

Removing l  Gearbox is secured to engine and gearbox support -VAS 6095- → Chapter. –  Remove flywheel → Chapter. –  Drain ATF → Chapter. –  Prise out oil seal for input shaft with extractor tool -T20143/2-.

–  Remove bolts -1 … 5-.

–  Turn gearbox into a vertical position on engine and gearbox support -VAS 6095-. –  Slide sleeve -T40123 A/1- onto input shaft. –  Position puller for ATF supply unit -T40123 A- on input shaft. l  Lip -arrow- of puller for ATF supply unit must reach underneath sleeve -T40123 A/1-. –  Close puller for ATF supply unit and tighten knurled nut -1- (to approx. 20 Nm). –  Check that puller for ATF supply unit is securely seated on input shaft.

–  Connect puller for ATF supply unit -T40123 A- to hook -10 - 222 A /2- and attach to workshop hoist -VAS 6100-. –  Carefully pull dual clutch out of gearbox housing.

–  Place dual clutch (with cover) down on a soft surface so that the thin collar -arrow A- is not damaged.

–  Remove circlip -arrow- using circlip pliers.

–  Detach clutch cover -2- from dual clutch -1-.   Note

t  If the clutch cover cannot be detached, knock lightly on the input shaft with a plastic hammer while a second mechanic lifts the clutch cover by hand. t  Take care not to damage the thin collar -arrow A-. Installing Installation is carried out in reverse sequence; note the following:   Note Renew O-ring and circlip. –  Clean sealing surface on clutch cover. –  Turn rectangular section seals -B- on hub and check for freedom of movement and axial play.   Note If any of the rectangular section seals do not move freely, the dual clutch must not be fitted.

–  Clean gearbox housing in area of dual clutch and clean sealing surface.   Note Make sure that no particles of dirt fall into the gearbox when cleaning the housing. –  Screw centring tool -T40199- into threaded holes in gearbox housing, as shown in illustration.

–  Check rotating port -arrow- in gearbox for scoring.

–  Lightly lubricate O-ring -C- and hub -B- of dual clutch with ATF before installation.

–  Insert dual clutch into gearbox housing, as shown in illustration (lift and rotate dual clutch slightly so that input shaft engages in splines on ATF pump and gearbox shafts). l  Dual clutch is installed correctly if contact can be felt between O-ring of clutch cover and edge of gearbox housing.

Caution t  The new O-ring must not be crushed during installation. t  It is important to tighten the bolts for the dual clutch and clutch cover in the correct sequence → Fig.. –  Renew oil seal for input shaft → Chapter. –  Install flywheel → Chapter. –  Fill up with ATF after installing gearbox → Chapter. l  After renewing dual clutch, run appropriate „Guided Function“ using vehicle diagnostic tester → Chapter