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-.

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

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

- 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.

  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:

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.

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.

- 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.

• The ball bearings are visible! -Arrow-

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

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.

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

- 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.

Procedure:

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

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