Clutch, General Information

Release Bearing 

• >>Rattling noises<< can occur when pressing the clutch if there is not enough grease on the release bearing areas -arrows-.
• Lubricate the bearing areas -arrows- on the release bearing with Grease G 000 150.

Clutch module 

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.

• Normal >>clicking<< in clutch module -A- with a dual mass flywheel with "LuK" centrifugal pendulum absorber.
  Fig 3: Turning Clutch Module -A- With Centrifugal Pendulum Absorber 90 Degrees (Clicking Noise Normal)

  Courtesy of AUDI OF AMERICA, LLC
• Depending on the version, the clutch module -A- is installed with or without a centrifugal pendulum absorber.
• A >>clicking<< is heard when turning the clutch module with the centrifugal pendulum absorber by hand approximately every 90°.
• This noise comes from a centrifugal pendulum absorber in the dual mass flywheel and is not a fault.

Input Shaft 

• If the surface of the input shaft is visibly damaged near the needle bearing in the dual mass flywheel -arrow-, then replace both the input shaft and the needle bearing. Refer to DUAL MASS FLYWHEEL NEEDLE BEARING OR BALL BEARING, REPLACING .
• Replace the drive shaft. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .
• Check the input shaft near the bearing in the drive plate -arrow- for wear grooves and replace the needle bearing in the drive plate if necessary. Refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING for engine(s) CAED, CAEB, CPMB, CPMA, NEEDLE BEARING IN DRIVE PLATE, REPLACING for engine CALA, and NEEDLE BEARING IN DRIVE PLATE, REPLACING for engine(s) CCBA, CGXC, CTUB .
  Fig 5: Checking Input Shaft For Scoring

  Courtesy of AUDI OF AMERICA, LLC
• Clean input shaft splines and the hub splines (on used clutch plates). Remove corrosion and apply a very thin coating of Grease for Clutch Disc Shaft Splines G 000 100 to the splines. Then move the clutch plate back and forth on the input shaft until the hub moves freely on the shaft. Remove any excess grease.
• Remove the grease on the pivot pin up to the splines.

Dual Mass Flywheel 

• The turning of the secondary flywheel mass -1- against the primary flywheel mass -2- respective to the stop -direction of arrow A- results from equal resistance and not being stuck.
• The stop on both sides is spring loaded.
• The secondary flywheel mass -1- adjusts itself to be level -direction of arrow B- against the primary flywheel mass -2-
  Fig 7: Secondary Flywheel Mass -1- Adjusts Itself To Be Level -Direction Of Arrow B-

  Courtesy of AUDI OF AMERICA, LLC
• The secondary flywheel mass -1- has tilting clearance -direction of arrow C- toward the primary flywheel mass -2-.
  Fig 8: Secondary Flywheel Mass -1- Has Tilting Clearance -Direction Of Arrow C-

  Courtesy of AUDI OF AMERICA, LLC
• Check which version of the needle bearing is installed inside the dual mass flywheel -A, B, C-. Replace the needle bearing if necessary. Refer to Figure.
  Fig 9: Checking Needle Bearing Inside Dual Mass Flywheel On Vehicles With 4-Cylinder TDI Engine (Except On 125 kW TDI)

  Courtesy of AUDI OF AMERICA, LLC
• Check the plastic washer -A- on the dual mass flywheel "manufactured by Sachs" for wear. Refer to Figure.
  Fig 10: Checking Dual Mass Flywheel

  Courtesy of AUDI OF AMERICA, LLC

Clutch plate, Clutch pressure plate 

• To prevent damaging the clutch pressure plate while removing or installing, pay close attention to the installation instructions. Refer to CLUTCH, REMOVING AND INSTALLING, "Sachs"  and CLUTCH, REMOVING AND INSTALLING, "LuK" .
• With clutch pressure plate (manufactured by LuK), an adjusting ring must be reset if only clutch plate is replaced. Refer to CLUTCH PRESSURE PLATE ADJUSTING RING, RESETTING, "LuK" .
• Check the clutch pressure plate for deformation. Refer to Figure and. Refer to Figure.
• The clutch pressure plates are corrosion-protected and greased. With the exception of the friction surface on the clutch plate, do not clean the clutch pressure plate. This will shorten the service life of the clutch considerably.
• The friction surfaces on the clutch pressure plate and on the dual mass flywheel must be cleaned thoroughly (degreased).
• Replace clutch plates and clutch pressure plates that have damaged or loose rivets.
• Installation position of the clutch plate: The spring pack (coil springs) or "Getriebeseite" (transmission side) label -arrow- must face the clutch pressure plate.
  Fig 12: Clutch Plate Installed Position

  Courtesy of AUDI OF AMERICA, LLC
• For the correct pressure plate and clutch pressure plate according to the engine codes.