Removing the Clutch

Above the clutch pedal (3) you can see the rubber boot (1) of the clutch master cylinder and both mounting bolts (2).

The centering arbor for the clutch disc is required as a special service tool for this work. This arbor is nothing other than the end of the transmission input shaft.

If no suitable tool is available, the clutch disc can be centered with another suitable arbor (steel pin, wooden dowel, etc.).

PROCEDURE

Remove the transmission.

Loosen the 8 mm internal Torx bolts on the pressure plate. If the flywheel turns together with the pressure plate, have an assistant insert a screwdriver into the ring gear teeth on the outer edge to prevent the flywheel from turning, bracing the screwdriver against a loosely installed transmission mounting bolt.

Remove the pressure plate and clutch disc.

Inspect the pressure plate for wear: Is there wear deeper than 0.3 mm on the diaphragm spring fingers? Are the diaphragm spring fingers bent? Are all rivets tight? Are the leaf springs under the friction ring in good condition? Are there cracks or grooves on the friction ring itself? In addition, the friction ring must not be warped toward the center by more than 0.3 mm (use a metal straightedge). Otherwise, replace the pressure plate.

Inspect the clutch disc for wear: Is there still enough friction material, or do the brass rivets protrude dangerously far (mostly on the pressure plate side first)? Audi does not specify an exact wear limit, so rely on your own judgment.

We recommend replacing the clutch components at the slightest suspicion. This will certainly save you from removing the clutch again in the near future. Next, check the disc torsion springs. If one of them is broken, install a new clutch disc.

Check the small needle bearing at the rear center of the crankshaft and the release bearing for seizing.

Lubricate the internal splines of the clutch disc with MoS2 paste or V.A.G. D 000 100 grease.

Apply a thin layer of heat-resistant grease to the spline grooves and the small needle bearing.

Install the clutch disc (spring side facing the pressure plate) and the pressure plate. Use the arbor to center the clutch disc on the flywheel (the center holes of both parts must align so that the transmission input shaft can slide on easily during later transmission installation).

Tighten the pressure plate bolts evenly in a crisscross pattern in several steps to 25 Nm.

Install the transmission.

Note: If you are installing a new clutch disc, be sure to remove the anti-corrosion wax coating from the friction surfaces with solvent. Otherwise, premature clutch wear will occur.

Release Bearing Removal
PROCEDURE

Remove the transmission.

Remove the release bearing.

If you are reinstalling the old bearing, note that it may only be wiped clean and must not be washed.

The guide sleeve on which the bearing moves in both directions is made of plastic and must not be lubricated.

For installation, simply slide the bearing onto the sleeve.