Clutch, servicing

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Clutch, Servicing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Counterhold tool 10 - 201
Locking bar 3067
Centering mandrel 3176
Torque wrench V.A.G 1331

Grease for clutch plate splines G 000 100

NOTE:

Refer to general repair instructions → General repair instructions .
Observe the notes on removing and installing master cylinder and slave cylinder → Notes on removing and installing master cylinder and slave cylinder .
On vehicles with SAC pressure plate (self-adjusting clutch, LuK version) an adjuster ring has to be reset when only the clutch plate is replaced → Adjuster ring in SAC clutch pressure plate, adjusting .
To avoid damaging SAC pressure plate when removing and installing, observe assembly instructions for SAC pressure plate → Clutch with SAC pressure plate, removing and installing .
Check that SAC pressure plate is not warped Check SAC pressure plate for warpage, cracks and burns
If the vehicle is installed with a self-adjusting clutch (Sachs version), the clutch plate and pressure plate can only be replaced together → Self-adjusting clutch (Sachs version), servicing .
Replace clutch plate and pressure plate if riveted fastening is damaged or loose.
Select correct clutch plate and pressure plate according to engine code
To avoid damaging dual-mass flywheel during removal please observe instructions for removal Removing dual-mass flywheel
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 G000100 to the splines. Then move clutch plate backward and forward on input shaft until hub moves freely on shaft. It is important to remove excess grease.
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.
If the clutch has burned out, thoroughly clean the bell housing, flywheel and parts of the engine facing the transmission in order to prevent odors.

Servicing conventional clutch → Conventional clutch, servicing

Servicing self-adjusting clutch (Sachs version) → Self-adjusting clutch (Sachs version), servicing

Servicing clutch with SAC pressure plate (LuK version) → Clutch with SAC pressure plate (LuK version), servicing