Clutch, servicing: Notes

WARNING: This page is about a different car, the 2004 Audi A4, 2003 Audi A4, and 2002 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 and equipment

3067 Counterhold
3176 Centering mandrel
VAG 1331 Torque wrench

NOTE:

Follow general repair instructions. Refer to General repair instructions .
Replace clutch plates and pressure plates where riveted joint is damaged or loose.
Assign clutch plate and pressure plate by way of engine code.
Clean input shaft splines and - in the case of used clutch plates - hub splines, remove corrosion and apply extremely thin layer of grease G 000 100 to splines. Then move clutch plate back and forth on input shaft until hub moves freely on shaft. Excess grease must be removed.
Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, as otherwise the clutch service life will be considerably shortened.
To reduce the odor nuisance of a scorched clutch, thoroughly clean bell housing, flywheel and parts of engine facing transmission.

Fig 2: Clutch Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

For servicing the clutch first remove the transmission. Refer to Transmission, removing and installing .

A - Paint dot on dual-mass flywheel

If present, white paint dot -A- on dual-mass flywheel must be aligned with white paint dot -B- on pressure plate

B - Paint dot on pressure plate

If present, white paint dot -A- on dual-mass flywheel must be aligned with white paint dot -B- on pressure plate

Fig 3: Clutch Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Dual-mass flywheel

Make sure centering pins are a tight fit
Locating face for clutch lining must be free from grooves, oil and grease
Removing and installing

Refer to 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

2 - Bolt for flywheel

Always replace
Bolt length 22.5 mm: 60 Nm 1/4turn (90 ° )
Bolt length 43 mm: 60 Nm plus 1/2 turn (180 ° )

Fig 4: Clutch Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

3 - Clutch plate

Installation position:

Damping set (coil springs) toward pressure plate or transmission
Lining of clutch plate must be located against flywheel
Writing "Getriebeseite", if present, toward pressure plate or transmission

Do not lubricate
Diameter of clutch plate. Refer to Code letters, assignment of mechanical units, transmission ratios and capacities onward
Centering. See Centering clutch plate and removing/installing pressure plate
Slightly lubricate splines

Fig 5: Clutch Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

4 - Pressure plate

Removing and installing. See Centering clutch plate and removing/installing pressure plate
Checking ends of diaphragm spring. See Checking ends of diaphragm spring
Checking spring attachment and rivet attachments. See Checking spring attachment and rivet attachments
If present, line up white paint dots on flywheel -A- and pressure plate -B-, with one another during assembly.

5 - Bolt, 25 Nm

Loosen and tighten gradually in diagonal sequence

6 - Needle bearing

Removing and installing

Refer to 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK