Remove gearbox.
Loosen the 8 mm socket bolts on the pressure plate. If the flywheel rotates with the pressure plate, have an assistant insert a screwdriver into the gearing on the outer edge and prevent the disc from rotating by resting the screwdriver on the baited gearbox mounting bolt.
Remove pressure plate and driven plate.
Assess the wear of the pressure plate: is it possible to find wear marks deeper than half the thickness at the end of the Belleville spring? Are the ends of the petals of the Belleville spring bent to the side? Are all rivets tight? Are the flat springs under the contact ring OK? Are there any cracks and grooves on the ring itself? In addition, towards the middle, the ring should not be bent more than 0.3 mm (attach a metal ruler). Otherwise, replace the pressure plate.
Assess the wear of the driven disk: is there still enough coating material or are the brass rivets already protruding dangerously far (for the most part, first from the side of the pressure plate)? Audi does not specify the exact degree of wear, so you need to rely on your own instincts.
Clutch master cylinder visible above clutch pedal (1) and connecting pipeline (2).
We recommend replacing clutch discs at the slightest suspicion. This will surely save you from having to remove the clutch again in the near future. Next, you need to check the coil springs of the disc. If one of them is broken, install a new disk.
Check the small needle bearing at the rear in the middle of the crankshaft and the release bearing for binding.
Lubricate the inner teeth of the driven disk with MoS2 paste or VW grease - Fett G 000 100.
Remove excess lubricant.
Apply a thin coat of heat-resistant grease to the keyways and small needle bearing.
Install clutch disc (spring towards pressure plate) and pressure plate, while using a mandrel to center the clutch disc on the flywheel (the central holes of both parts must match so that they can be easily put on the gearbox shaft during the subsequent installation of the gearbox).
Tighten pressure plate crosswise in several passes to 25 Nm.
Install gearbox.
Note: If you are installing a new clutch disc, be sure to remove the rust protection wax on the friction surface with a solvent. Otherwise, premature clutch wear awaits you.
Removing the release bearing
Remove gearbox.
Remove release bearing.
If you are reinstalling an old bearing, please note that it can only be wiped down and must not be washed.
The guide sleeve, along which the bearing moves in one direction and the other, is made of plastic and must not be lubricated,
To install, simply slide the bearing into the sleeve.
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