Audi A4 Owners & Service Manuals

Audi A4: Dual Clutch, Removing and Installing

Special tools and workshop equipment required

  • Shop Crane -VAS6100-
  • Puller - Input Shaft -T40050-
  • Pressure Stand -T40099-
  • Guide Pins - Gearbox -T40288-
  • Engine Support Bridge - Additional Hooks (2 pc.) -10-222A/2-

Removing

  • Secure the transmission on the Engine And Transmission Holder -VAS6095-. Refer to → Chapter "Securing on Engine and Transmission Holder".

- Remove the flywheel. Refer to → Chapter "Flywheel, Removing and Installing".

- Turn the transmission in the Engine and Gearbox Bracket -VAS6095A- so that it is vertical.

- Remove the bolts -1 to 12-.

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- Place the Puller - Input Shaft -T40050- on the input shaft clutch and lock -arrows-.

- Make sure the puller is secure on the input shaft.

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- Connect the Puller - Input Shaft -T40050- with the Engine Support Bridge - Additional Hooks (2 pc.) -10-222A/2- and engage in the Shop Crane -VAS6100-.

- Carefully remove the dual clutch out of the transmission housing.

  Caution

When removing, the engaging bearing and both alignment sleeves can fall out of the transmission housing.

A damaged or dropped engaging bearing must be replaced.

  Note

  • The dual clutch is extensively calibrated on the engaging bearing and slave cylinder.
  • Calibrating with service equipment is not possible.
  • A damaged engaging bearing or slave cylinder must for this reason always be replaced with a new clutch.
  • A new clutch is always supplied with a calibrated engaging bearing and slave cylinder.

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  Caution

There is a risk of damaging the dual clutch from mishandling.

  • The hub for "clutch 2" -arrow- is clipped in the inner disk support and can be loosed through mishandling of the clutch.
  • Transport and position the clutch only as shown:

Dual Clutch, Removing and Installing

It can be checked by measuring the height dimension if the clutch is damaged.

- Remove the three bolts -arrows- and remove the engaging bearing with the slave cylinder.

  Note

Depending on the version the three bolts -arrows- may not be present.

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Installing

  Note

The double shaft seal for the input shaft must always be replaced! Refer to → Chapter "Input Shaft Double Shaft Seal, Replacing".

- Check if the sleeves -1 and 2- are installed.

- Coat the new seals -3, 4 and 5- with ATF and install.

- Insert the seal -6-.

  Note

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

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- Install the engaging bearing with the slave cylinder and tighten the three bolts -arrows- evenly.

  Note

Depending on the version the three bolts -arrows- may not be present.

  Note

  • Pay attention that the engaging bearing is installed correctly to the slave cylinder.

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  • The ball bearings are visible! -Arrow-

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- Install the Guide Pins - Gearbox -T40288- in the threaded hole approximately 120º offset.

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Check the Clutch Installation Height

  • Before installing the clutch the dimension -x- must be determined.
  • To do so use the Ruler (2 pc.) -T40100- and Digital Depth Gauge -VAS6087- to determine the height of the clutch cover to the hub offset as shown.

The dimension -x- must be located within the tolerance of 98.91 to 99.61 mm.

  Note

If the dimension -x- is outside of the tolerance, the clutch must be replaced because it is damaged.

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- Place the dual clutch as shown in the transmission housing.

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- Tighten the bolts -1 to 12- for the clutch cover diagonally in steps. Tightening specification. Refer to → Chapter "Overview - Flywheel and Dual Clutch".

- Install the flywheel. Refer to → Chapter "Flywheel, Removing and Installing".

  • After installing the transmission fill the ATF and transmission fluid. Refer to → Rep. Gr.34; ATF; ATF, Draining and Filling and → Rep. Gr.34; Transmission Fluid; Transmission Fluid, Draining and Filling
  • After changing the dual clutch the clutch must be adapted. Refer to Vehicle Diagnostic Tester.

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Procedure:

  • Drivetrain
  • 0CK Transmission
  • 01 OBD-capable systems
  • 02-Transmission electronics
  • 02-Transmission electronics, functions
  • 02-Basic Setting
  • 04-Adapt clutch slip points

    READ NEXT:

     Input Shaft Double Shaft Seal, Replacing

    Special tools and workshop equipment required Puller - Crankshaft/Power Steering Seal -T20143- Thrust Piece -T40300- Clutch, engaging bearing and slave cylinder removed. Refer to → Chap

     Controls, Housing

     Transmission, Transporting

    Special tools and workshop equipment required Shop Crane -VAS6100- Lifting Tackle -3033- Hook And Support Tool -3311- with Hook And Support Tool - Bolt -3311/1- Retaining Strap -T40155-  

    SEE MORE:

     Flywheel, Removing and Installing

    Special tools and workshop equipment required Puller - Clutch Module -T40176- Clutch Disc Shaft Spline Lubricant -G 000 100- Sealing Grease. Refer to the Parts Catalog. Removing   Note There is a normal "clicking" in the dual mass flywheel with "LuK" centrifugal pendulum absorber -A-.

     Special Tools

    Special tools and workshop equipment required Used Oil Collection and Extraction Unit -SMN372500- Tensioning Strap -T10038- Seal Installer - Selector Shaft -T10135- Engine/Gearbox Jack - Gearbox Support -T10337- Torx Socket - T60 -T40087- Clutch Module Assembly Aid -T40169-

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