Audi A4 Workshop Service and Repair Manuals

Removing and installing clutch module Special tools and workshop equipment required

t  Extractor -T40176-

t  Puller -T10037-

t  Multi-purpose tool -VW 771/1- t  Grease for clutch plate splines -G 000 100- t  Sealing grease -G 052 128 A1- Removing clutch module

–  Remove the gearbox and secure in position with a tensioning strap -1- on the gearbox support -T40173- → 6-speed manual gearbox 0B3, 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.

–  Unscrew bolts -arrows- on mounting bracket for flange shaft (left-side).

–  Remove flange shaft from gearbox in direction of -arrow A-. Keep shaft end -2- centered in opening on front final drive -arrow 3-.   Caution Risk of damage to oil seal. t  If you do not keep the shaft centered when pulling it out further, the splines of the shaft -2- will fall against the inner oil seal -arrow 3- between the differential and the gearbox housing. t  If oil seal is damaged, it must be renewed → Chapter.   Note

If the flange shaft (left-side) cannot be removed by hand, pull it out carefully using multi-purpose tool -VW 771-. –  To do this, secure plate of puller -T10037- to flange shaft -arrows- and attach plate to spindle of multi-purpose tool -VW 771- (nuts -A-).

–  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.

Installing clutch module Installation is carried out in reverse sequence; note the following: –  Grease clutch release bearing according to specifications → Fig.. –  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-.

–  Clean input shaft -arrow-. –  Apply a thin coat of grease for clutch plate splines -G 000 100- to the splines of the 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.

–  Turn clutch module -1- so that you can see opening to differential -arrow 3-. –  Slide flange shaft (left-side) into gearbox in direction of -arrow B- (keep end of shaft -2- centered while guiding it into oil seal on final drive -arrow 3-).   Caution Risk of damage to oil seal. t  If you do not keep the shaft centered, the splines of the shaft -2- will damage the oil seal -arrow 3- between the differential and the gearbox housing. t  If oil seal is damaged, it must be renewed → Chapter.

–  Tighten flange shaft mounting bracket -arrows-. Tightening torque → Item.