Clutch — removal and installation (Audi 80 B4)

To carry out work on the removal and installation of the clutch, a rod is required to center the clutch disc. This rod can replace the old transmission input shaft.

1. Remove the gearbox.

2. Turn out 8 mm bolts with an internal polyhedron on a pressure plate. To prevent the engine flywheel from turning at the same time, lock it with a suitable screwdriver, fixing it on the flywheel ring gear.

3. Disconnect and remove pressure and driven clutch discs.

4. Inspect the pressure plate for wear.

5. Check the condition of the diaphragm spring segments and make sure that the wear of the run-in segments does not exceed 0.3 mm.

6. Make sure the diaphragm spring segments are not bent and the rivets are firmly seated.

7. Check the bearing surface of the pressure plate for cracks, nicks and wear. Discs with an inward deflection of up to 0.3 mm can still be installed. Check with a metal ruler. In the presence of these shortcomings, the pressure plate must be replaced.

8. Check the condition of the slave drive. AUDI does not provide any guidelines regarding wear of the driven disc. We recommend that you rely on your own judgment and change the drive if you have any doubts.

9. Check the damper springs on the disc. If at least one of them is broken, then the disk must be replaced.

10. Check the small needle bearing at the end of the crankshaft to center the transmission input shaft, and the clutch release bearing for ease of movement.

11. Lubricate the splined grooves of the clutch disc with molybdenum paste or VAG D 000 100 grease.


12. Grease grooves of an input shaft shaft of a transmission, and also the needle bearing with temperature-resistant grease.

13. Reinstall the clutch disc. The rear damper plate must face the pressure plate.

14. Install the pressure plate and center the driven plate using the old gearbox input shaft or a suitable rod or mandrel.

15. Screw in the pressure plate mounting bolts and tighten them in several passes in a cross pattern with a torque of 25 Nm.

Attention! When installing a new pressure plate, be sure to remove anti-corrosion grease from its active surface. It can be washed off with a thinner. Otherwise, the service life of the pressure plate is reduced.

16. Reinstall the gearbox.

To replace the release bearing, the transmission must also be removed. If the old bearing will be installed, then do not remove the grease from it. The clutch release bearing is plastic, so it does not need to be lubricated. In order to install the release bearing in place, it is enough to insert it into the clutch.