Dual Clutch, Installing

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Install in reverse order of removal. Note the following:

NOTE:

Replace the O-ring and the circlip.

-- Clean the sealing surface on the clutch cover.

-- Turn the rectangular rings -B- on the hub and check for ease of movement and axial play.

NOTE:

If the rectangular rings do not move easily, then the dual clutch must not be installed.

-- Clean the transmission housing around the dual clutch and the sealing surface.

Fig 1: Identifying Special Tool Placement, T40199

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Make sure no dirt can fall into the transmission while cleaning.

-- Install the Oil Sump Assembly Pin T40199 into the threaded hole in the transmission housing as illustrated.

-- Check the hole -arrow- in the transmission for wear grooves.

Fig 2: Checking Transmission Hole For Wear

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-- Coat the O-ring -C- and hub -B- on the dual clutch with ATF.

Fig 3: Identifying Dual Clutch Components

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-- Install the dual clutch into the transmission housing. Using short lifting/turning motions, allow the input shaft to engage into the ATF pump splines and transmission shafts as illustrated.

Fig 4: Remove/Install Dual Clutch Components

Courtesy of AUDI OF AMERICA, LLC

The dual clutch is installed correctly when the clutch cover O-ring noticeably contacts the edge of the transmission housing.

Fig 5: Clutch Cover Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Do not let the O-ring get caught when installing.
Always follow the tightening sequence when tightening the clutch cover bolts -1 through 5-. Refer to (Figure).

-- Tighten the clutch cover bolts -1 through 5- to the tightening specification and sequence. Refer to Figure.

-- Replace the input shaft seal. Refer to INPUT SHAFT SEAL, REPLACING .

-- Install the flywheel. Refer to FLYWHEEL, REMOVING AND INSTALLING .

-- Fill with ATF after the transmission is installed:

-- After installing the transmission, fill the ATF. Refer to ATF, DRAINING AND FILLING .

Perform the relevant "Guided Function " using the vehicle diagnostic tester after replacing the dual clutch. .