Clutch Module, Removing And Installing

WARNING: This page is about a different car, the 2013 Audi S4, 2012 Audi S4, 2011 Audi S4, and 2010 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Puller - Clutch Module T40176
Puller - Flanged Shaft T10037
Slide Hammer Set - Hammer VW771/1
Grease for Clutch Disc Shaft SplinesG 000 100
Sealing Grease G 052 128 A1

Remove the Clutch Module

-- Remove the transmission and secure it to the Gearbox Support T40173 using a tensioning strap -1-. Refer to TRANSMISSION, REMOVING AND INSTALLING .

Fig 1: Identifying Transmission Holding Fixture

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Tilt the transmission back slightly to prevent transmission fluid from leaking when removing the left flange shaft.

-- Remove bolts -arrows- on left flange shaft mounting bracket.

Fig 2: Identifying Bolts & Flange Shaft Mounting Bracket

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-- Remove the flange shaft from the transmission in the direction of arrow -A-. Keep the end of the shaft -2- centered on the front final drive opening -arrow 3-.

Fig 3: Identifying Left Flange Shaft

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CAUTION:

Danger of damaging the shaft seal.

If the shaft is not centered when removing, the shaft splines -2- fall onto the inner shaft seal -arrow 3- between the final drive and the transmission housing.
Always replace a damaged shaft seal. Refer to LEFT SEAL, REPLACING .

NOTE:

If it is not possible to remove the left flange shaft by hand, then use the Slide Hammer SetVW771 to remove it.

Fig 4: Attach Plate From T10037

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-- Attach the plate from the Puller - Flanged Shaft T10037 to the flange shaft -arrows- and attach the spindle from the Slide Hammer SetVW771 (nuts -A-).

-- Attach the Puller - Clutch Module T40176 to the clutch module -A- with the nut -B- -arrow-.

Fig 5: Identifying Nut

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-- Turn the Puller - Clutch Module T40176 upward.

Fig 6: Identifying Flywheel Components, Remove/Install

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CAUTION:

Danger of damaging the shaft seals and the needle bearings in the dual mass flywheel.

The clutch module weighs approximately 20 kg (44 lbs.).
To prevent the clutch module from tipping, counterhold it at the bottom as shown in the illustration.
When removing and installing the clutch module, make sure the shaft seals and the needle bearing in the dual mass flywheel -arrow- are not damaged.
Replace the damaged shaft seals or needle bearings. Refer to DUAL MASS FLYWHEEL NEEDLE BEARING, REMOVING AND INSTALLING .

-- Remove the clutch module without tilting the input shaft -arrow-.

Fig 7: Identifying Transfer Plate

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CAUTION:

Danger of causing damage to the transfer plate on the dual mass flywheel.

Do not lay the clutch module on one side on the transfer plate -arrow-.
This could bend the transfer plate -arrow-, which will then lead to functionality problems.

-- Lay the clutch module on a work bench with the clutch pressure plate facing down.

Install the Clutch Module.

Fig 8: Carefully Set Down Electro-Drive Drive Motor

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Install in reverse order of removal. Note the following:

-- Lubricate the release bearing according to the specification. Refer to Figure.

-- Always clean the left flange shaft, the transmission housing in the area where the differential is accessed -arrow A- and the shaft seal -arrow B-.

NOTE:

Replace the shaft seal between the differential and transmission housing -arrow B- if it is damaged. Refer to LEFT SEAL, REPLACING .

-- Fill the space between the sealing and dust lip -arrow B- halfway with Sealing Grease G 052 128 A1.

-- Clean the input shaft -arrow-.

Fig 9: Identifying Flywheel Components, Remove/Install

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-- Lubricate the input shaft splines using Grease for Clutch Disc Shaft SplinesG 000 100.

CAUTION:

Remove any grease on the pivot pin on the input shaft -arrow- all the way up to the splines before installation.

-- Slide the clutch module onto the input shaft carefully without tilting it.

-- Remove the Puller - Clutch Module T40176 from the clutch module.

-- Rotate the clutch module -1- until the opening to the differential -arrow 3- is seen.

Fig 10: Identifying Left Flange Shaft

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-- Insert the left flange shaft into the transmission in the direction of -arrow B- and guide the end of the shaft -2- into the shaft seal on the front differential -arrow 3-, keeping the shaft centered.

CAUTION:

Danger of damaging the shaft seal.

If the shaft is not centered, the shaft splines -2- will damage the shaft seal -arrow 3- between the differential and transmission housing.
Always replace a damaged shaft seal. Refer to LEFT SEAL, REPLACING .

-- Tighten the left flange shaft mounting bracket -arrows-. Tightening specification: 24 Nm

Fig 11: Identifying Bolts & Flange Shaft Mounting Bracket

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