Removal the clutch (Audi 100 C4)

Of the special tools for this job, you will need a centering dory for the driven disk. This mandrel is nothing more than the end of the primary shaft of the gearbox. In the absence of a better one, you can center the clutch disc with another suitable mandrel (steel pin, wooden pin, etc.).

Remove the gearbox.

Loosen the 8mm internal hexagon bolts on the pressure plate. If the flywheel rotates with the pressure plate, have an assistant insert a screwdriver into the gear engagement on the outer edge and prevent the plate from rotating by bracing the screwdriver against the tacked transmission mounting bolt.

Remove the pressure plate and driven disk.

Assess the wear of the pressure plate: can you find wear marks deeper than half the thickness on the end of the disc spring? Are the ends of the disc spring petals bent to the side? Are all the rivets firmly held? Are the flat springs under the contact ring in order? Are there any cracks or grooves on the ring itself? In addition, the ring should not be bent more than 0.3 mm towards the middle (apply 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? (mostly from the pressure plate side first)? Audi does not specify the exact degree of wear, so you have to rely on your own instinct.



We recommend replacing the clutch discs at the slightest suspicion. This will certainly save you from having to remove the clutch again in the near future. Next, you need to check the disc coil springs. If one of them is broken, install a new disc.



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

Lubricate the internal gear engagement of the driven disk with MoS2 paste or VW-Fett G 000 100 consistent grease.

Remove excess grease.

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

Install the clutch disc (spring towards the pressure plate) and the 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 placed on the gearbox shaft when the gearbox is subsequently installed).

Tighten the pressure plate in several stages, crosswise, to a torque of 25 Nm.

Install the gearbox.

Note: If you are installing a new clutch disc, be sure to remove the wax rust protection on the friction surface with solvent. Otherwise, you will experience premature clutch wear.

Removal the release bearing

Remove the gearbox.

Remove the release bearing.

If you are reinstalling an old bearing, please note that it can only be wiped and cannot be washed.

The guide bushing along which the bearing moves in one direction and the other is made of plastic and cannot be lubricated,

To install, simply push the bearing into the sleeve.

(Information obtained from this resource: AUDIMANUAL.RU)