Audi Workshop Service and Repair Manuals

Removing and installing clutch module Special tools and workshop equipment required

t  Extractor -T40176- t  Grease for clutch plate splines -G 000 100-

Removing –  Remove gearbox and secure to gearbox support -T40173- using tensioning strap -1- → 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr.34. l  Gearbox must be inclined slightly to the rear so that gear oil does not escape after flange shaft (left-side) is removed.

–  Remove flange shaft (left-side) → Chapter.

–  Attach extractor -T40176- to clutch module -A- using nut -B--arrow-.

–  Turn extractor -T40176- upwards.   Caution Risk of damage to oil seals and needle bearing in dual-mass flywheel. t  The clutch module weighs approx. 20 kg. t  Keep firm hold of the bottom of the clutch module, as shown in the illustration, to prevent the clutch module from tilting over. t  When removing and installing the clutch module, take care not to damage the oil seals and needle bearing in the dual-mass flywheel -arrow-. t  Renew oil seals or needle bearing if damaged → Chapter. –  Pull clutch module off input shaft -arrow-, keeping clutch module straight.

Caution Take care not to damage flange for drive plate on dual-mass flywheel. t  Do not put down clutch module with flange -arrow- for drive plate facing downwards. t  This could bend the flange -arrow- for the drive plate, which would cause problems with clutch operation. –  Put clutch module down carefully, e.g. on work bench, with pressure plate facing downwards.

Vehicles with 4-cylinder TDI engine (except 125 kW TDI)   Caution Check version of needle bearing in dual-mass flywheel. t  The needle bearing of the type where every 4th roller is missing -arrows- must always be renewed on vehicles with 4-cylinder TDI engine (except 125 kW TDI) → Chapter. t  New needle bearings have the full number of rollers. t  On all other vehicles the missing needle rollers do not mean that the needle bearing is defective. Do not renew the needle bearing.

Installing clutch module Installation is carried out in reverse sequence; note the following: –  Thoroughly clean flange shaft (left-side), area of gearbox housing leading to differential -arrow A- and oil seal -arrow B-.   Note If oil seal between differential and gearbox housing -arrow B- is damaged, it must be renewed → Chapter. –  Pack space between sealing lip and dust lip -arrow B- half full with sealing grease -G 052 128 A1-.

–  Grease clutch release bearing according to specifications → Fig.. –  Clean splines and bearing journal of input shaft -arrow-. –  Apply a thin coating of grease for clutch plate splines -G 000 100- to splines on input shaft.   Caution Before installing clutch module, remove grease from input shaft bearing journal -arrow- as far as splines.

–  Carefully slide clutch module onto input shaft taking care to keep clutch module straight. –  Detach extractor -T40176- from clutch module. –  Install flange shaft (left-side) → Anchor.