Best Audi A4 B5 A4 1.8Tq Clutch Replacement
Title : Best Audi A4 B5 A4 1.8Tq Clutch Replacement
link : Best Audi A4 B5 A4 1.8Tq Clutch Replacement
Best Audi A4 B5 A4 1.8Tq Clutch Replacement
DISCLAIMER: This data is presented only every bit a guide. Due to changes from year-to-year together with options-to-options it may non live totally accurate. I tin non live held responsible for anything that happens every bit a number of using this guide.
This is non something that should live attempted past times individual who has never worked on a car, or has piddling sense amongst them.
If you lot exercise this guide, I solely inquire ii things:
1. Accept the disclaimer,
2. Provide Feedback - comments/tips/problems/differences.
There, forthwith that that's out of the way, let's begin.
Tools needed
- Jack
- Jackstands
- Transmission jack - I borrowed mine from my uncle, it's from Sears, together with has an angle adjuster together with strap to continue the trans on the jack.
- Impact wrench
- 6mm allen socket
- 7mm allen socket
- 8mm allen socket
- 6mm allen wrench
- 8mm allen wrench
- 10mm socket (3/8" drive)
- 13mm socket (3/8" drive)
- 15mm shallow socket (3/8" drive)
- 15mm deep socket (3/8" drive)
- 15mm wrench
- 15mm "shorty" wrench
- 16mm shallow socket (3/8" drive)
- 16mm deep socket (3/8" drive)
- 16mm wrench
- 16mm "shorty" wrench
- 17mm shallow socket (3/8" drive)
- 17mm deep socket (3/8" drive)
- 17mm comport on socket (1/2" drive)
- 17mm wrench
- 17mm "shorty" wrench
- 18mm wrench
- 22mm wrench
- 3/8" drive ratchet
- 12" extension w/swivel end
- 6" extension
- 3" extension
- screwdriver
- phillips screwdriver
- Torque wrench
- Plug for coolant hose (I used a 3/8" bolt)
- 6 betoken T40 Torx bit
- 12 betoken T40 Torx chip - special tool???
- Loc-Tite
- Patience
- Common Sense
- fan (gotta continue cool, right?)
If you're planning on changing the trans fluid, at that topographic point are some special tools required. On my auto it required a 17mm allen wrench (fill plug) together with "3357 triple foursquare socket" (drain plug) I bought the 3357 from http://www.zelenda.com together with made the allen from a 17mm bolt welded to an onetime 1/2" drive socket.
I, of course, had these sitting inward my toolbox, inward the dorsum of my car, 180 miles away :( So I made a novel fill upward plug remover past times welding a nut to bolt, together with using a wrench on the nut, which turned the bolt, which turned the fill upward plug. I hence picked the trans upward together with drained it through the fill upward plug. I used Redline MTL (75w90) fluid, it takes 2.9 quarts.
If you lot produce modify the fluid, produce it after you're done. Wouldn't desire to receive got the jeopardy of spilling fluid inward the expanse you lot volition live working in/on for the side past times side several hours.
Parts
- Flywheel
- Clutch
- Pressure plate
- Flywheel bolts (shorter than stock bolts)
- Pressure plate bolts (same every bit stock bolts)
- Throwout bearing
- Clutch alignment tool - non necessary, but helpful
- Driveaxle or driveshaft bolts - inward illustration you lot muck upward the ones you lot have.
- New lock-nuts for the turbo - Bentley manual says to supervene upon them, I didn't
- New drive axle together with driveshaft seals - Bentley manual says to supervene upon them, I didn't
Instructions - Removal
I am next the Bentley manual for the most part. There are some steps I skipped, some that demand to live added, together with others that tin live done differently. I'm posting the steps together with providing to a greater extent than information amongst them. If you lot are attempting this, you lot should receive got this manual already. It contains many other things, particularly the required torque values for the bolts.
1. Disconnect terra firma cable from battery - 10mm
2. Remove driveshaft - ignore this step, it's non necessary
3. Remove airbox - come across pic
- Disconnect MAF connector
- Disconnect Power Output Stage connectors (see motion-picture present - 1)
- Disconnect Solenoid Valve for Wastegate Bypass Regulator Valve connector (see motion-picture present - 2)
- Disconnect EVAP canister purge regulator valve connector (see motion-picture present - 3)
- Disconnect hoses
- Pull airbox out
My auto has a custom cone air setup, which is why the POS is mounted on aluminum together with bolted to the fender.
4. Remove coolant tank together with laid aside
- take iii screws from top (phillips)
- Lift upward together with disconnect sensor from bottom (careful)
- take top coolant line together with plug.
- Leaving the bottom hose (big hose) connected, rotate the tank around virtually 135 degrees together with lay it down
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| Coolant tank sitting seat together with O2 sensor connectors. |
5. Disconnect instant O2 sensor connector from nether the coolant tank (leftmost connector - come across pic) together with costless the wiring from whatsoever ties.
6. Remove O2 sensors. The manual does non country to produce this, but I did it. Trying to take the truthful cat is hard plenty without having to worry virtually breaking the O2 sensors too. Takes a 22mm wrench together with a piddling elbow grease. You'll in all likelihood receive got to rail downwards the connector for the master copy O2 sensor, or you lot mightiness mayhap twist the wires plenty to suspension them (mine didn't break, but the jacket/insulator on ane wire opened up.)
7. Remove nuts from cat-to-turbo connection. Three 17mm nuts. The shorty wrench volition come upward inward handy for the bottom nut.
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| The nuts together with O2 sensor receive got been removed |
8. Remove trans-to-engine bolts that you lot tin larn to from above. I mean value at that topographic point were iii accessible from inward a higher house (left, middle, together with right) 16mm.
9. Remove engine pan/cover from underneath - 10 screws: 3 front, 3 back, 2 inward each cycle well.
10. Remove bracket for engine pan/cover - 2 bolts (13mm I think)
11. Jack auto upward together with pose on jack stands. I'm non actually sure enough of a proficient house to pose the jackstands, I forthwith receive got ii slight dents inward the floorboard of my car.
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| Car upward inward the air. Possibly bad spot for jack stands. |
12. Remove heatshield from rider side drive axle. Three 6mm allen bolts, ii accessible amongst an allen socket (left together with right) together with the top bolt requires an allen wrench.
13. With the auto supported on jack stands, house slight pressure level on the trans amongst a jack.
14. Unbolt rider side mount/support (leave mountain connected to support) - ii 13mm bolts, together with iii 8mm, again, ii accessible amongst an allen socket (left together with right) together with the top bolt requires an allen wrench. Also take the leap mountain from the downpipe. You tin allow the jack pressure level off the trans now, it volition live fine without.
15. Loosen clamping sleeve on downpipe-to-exhaust connection. You're supposed to live able to slide the clamping sleeves forward, but I couldn't larn it to budge, together with ended upward pulling the downpipe out of it instead.
16. Remove the cat/downpipe past times pulling it out from nether the car. I made the error of trying to larn it out from the top. I did finally larn it amongst a lot of swearing together with fidgeting. Oh well.
 |
| Catalytic converter together with downpipe |
17. Remove RPM sensor from transmission. My auto did non receive got this. If it did, it would live located on the driver's side of the transmission, inward a higher house the flywheel (about the ii o'clock seat if looking at the forepart of the trans).
18. Now the fun role (1st of many) Disconnect the driveaxles. The shafts are bolted inward amongst 6 12 betoken torx-head bolts. I was able to exercise a regular 6point T-40 torx chip to take them, but I highly recommend trying to larn the 12 betoken chip to trim down the jeopardy of rounding ane of these things off.
19. Disconnect Speed sensor together with opposite lite connectors on driver's side of the trans. Make sure enough no other connectors are attached.
20. Remove starter, ii 16mm bolts together with ane 6mm allen bolt. The wires tin remain connected. This tin live done ane of ii ways: The long together with painful way, or the brusk together with painful way.
- Long way: Remove bumper, take A/C belt, take A/C pump, take starter.
- Short way: Attempt to larn at 6mm allen bolt amongst an allen wrench past times maneuvering your paw together with arm through the A/C lines. When finally out (wait until you lot receive got to pose it dorsum in) take the ii starter bolts, slide the starter forrad together with elbow grease to lay it aside somehow.
21. Disconnect shift rod, ane 10mm bolt
22. Disconnect shift pin rod - ane 8mm (may receive got been 6mm, non sure) allen bolt. Space is tight requiring the exercise of an allen wrench. When it's out to the betoken that the allen wrench hits the trans tunnel, take the allen wrench together with assay out turning the bolt or washer on the backside amongst your fingers.
23. Remove the oestrus shield for the driveshaft. My auto did non receive got this.
24. Remove the driveshaft from the trans - 6 T-40 Torx bits, allow it hang on the oestrus shield.
25. Remove the iv engine-to-trans bolts on the bottom (all 16mm), together with at that topographic point should live exactly ii left belongings it together afterwards.
26. Place transmission jack nether the trans together with pose pressure level on it.
27. Remove driver's side trans mount-to-support bolt (8mm allen bolt), leave of absence the back upward bolted to the trans.
28. Remove the lastly ii engine-to-trans bolts.
29. slide trans together with trans jack dorsum exactly plenty for the bell housing to clear the pressure level plate.
30. Lower trans exactly plenty to larn access to the clutch slave cylinder. While lowering the trans, DO NOT LET THE INPUT SHAFT HIT THE PRESSURE PLATE "FINGERS" The clutch cylinder is held inward amongst a 6mm allen bolt, together with volition receive got a piddling chip of wiggling to larn it out. Careful, it's made of plastic. Do NOT take the line, together with produce NOT press the clutch pedal.
31. Make sure enough all drive axles are clear of the trans together with lower it. You mightiness receive got to describe the trans off the jack to slide/drag it out from nether the car, or you lot tin exactly leave of absence it nether the car, together with slide it out of the way.
 |
| Empty trans tunnel. |
 |
| Parts removed |
1 - Passenger side trans mountain together with related bolts
2 - Exhaust clamp bolts
3 - Passenger side drive axle shield together with related bolts
4 - Starter Bolts
five - Engine-to-Trans bolts
6 - Turbo-to-downpipe nuts
seven - Exhaust hanger spring
8 - Driveshaft bolts
ix - Clutch slave cylinder bolt
10 - Driver side trans support-to-mount bolt
eleven - Drive axle bolts
12 - Coolant tank screws
xiii - Just a rag, ignore it :)
Removing the clutch/flywheel
1. Remove the 6 6mm allen caput bolts from the pressure level plate together with take it together with the clutch plate. Influenza A virus subtype H5N1 screwdriver mightiness live needed to gently pry it off. Careful, the pressure level plate is the solely matter belongings the clutch plate in, together with it WILL autumn if you're non paying attention.
2. Bust out the comport on wrench to loosen the 6 17mm flywheel bolts. You in all likelihood don't demand the impact, but you lot volition pass a rattling long fourth dimension trying to larn the bolts unloose without one.
Installing the clutch/flywheel
1. Look at the flywheel together with you'll uncovering the bolt holes are irregular. The flywheel solely goes on ane way. when you lot receive got all 6 bolts in, torque them down. I held a screwdriver betwixt a flywheel molar together with the block spell tightening. The manual calls for 44 ft lbs + ninety degrees. The shorter bolts for the novel flywheel in all likelihood don't require the ninety marker turn. Check amongst APR to live sure.
2. Put the clutch disk together with pressure level plate on, the clutch disk has to become inward a sure enough means (the taller middle side goes towards the pressure level plate) Start putting the bolts in, but don't tighten yet. You demand to centre the clutch disk inward the pressure level plate. I eyeballed it since I didn't receive got the alignment tool. Torque the bolts inward stages inward a triangular fashion when it's centered.
Time it took me to larn this far, virtually seven hours.
Take a break, the hardest role is virtually to begin.....
1. With the transmission on the transjack (if it has an angle adjuster, brand sure enough it's on the right side), tardily elevator it into place, making sure enough that null is inward it's way. You volition demand to tally the angle of the engine amongst the angle of the jack. You volition receive got to slide the trans inward a little, jack it up, slide it in, jack it up, etc until the trans is aligned withe the engine. It may assistance to receive got a greater angle on the trans, together with when it's lined up, equal the angles out. DO NOT LET THE INPUT SHAFT HIT THE PRESSURE PLATE FINGERS. If ane of them bends, bad things happen.
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| Jack on transjack - uncovering the the dents from the jackstands. |
2. Put the clutch slave cylinder dorsum on. Trust me on this one, produce it now, earlier the trans is connected.
3. Now the fun part, inserting the trans. Mine slid right in, but if it doesn't, retrieve patience is the key. Put the trans inward gear together with assay out rotating the driveshaft end. this rotates the input shaft, together with may assistance align it. If all else fails, describe the trans out (careful if the slave cylinder is bolted on), together with depository fiscal establishment check to brand sure enough the clutch is even hence centered.
4. The trans in all likelihood wont slide all the means in. Get it inward plenty to larn a bolt started on either side (start amongst the bolts that become through the guide pins.
5. Basically, everything else is the opposite of removal, exactly a piddling to a greater extent than difficult.
Reassembly time, virtually 8 hours.
Things to avoid (aka what I did wrong)
1. Remove the cat/downpipe from the bottom. It volition come upward out from the top amongst a lot of struggling, yanking, together with cursing, or it volition driblet right out the bottom amongst slight maneuvering.
2. when putting the transmission in, I got the shifter pin arm caught betwixt the trans together with the hull, together with bent it straight. I establish this out after I had everything in, together with realized I couldn't shift into 1st, 3rd, or 5th. The shift rod wouldn't come upward dorsum far plenty because it striking the shifter pin arm. Influenza A virus subtype H5N1 jack together with a 2ft long 2x4 promptly bent the arm dorsum into cast :)
3. I tried to pose the clutch slave cylinder on after the trans was installed. I could non larn it to compress plenty to install. I had to cleft opened upward the bleed screw together with hence force it inward (I had a hose together with container hooked upward to choose handle of the fluid), together with hence bled the clutch organisation subsequently (not a large bargain though)
4. My APR flywheel/clutch was used together with didn't receive got whatsoever bolts amongst it. I had to cutting 5/8" off the goal of the flywheel bolts inward lodge to exercise them.
Notes/Comments/Suggestions:
Plan on a weekend for this job. Start Fri night, together with if all goes well, you lot should live done Sat night, or Dominicus morning.
I started Th black virtually 10pm, worked until the trans was out at 4am. I started in ane lawsuit again Fri black virtually 9pm, worked until 4am together with finished upward a span piddling things Sat afternoon.
I should also country that my clutch together with centre Torsion were replaced virtually 10 months agone (25K miles) hence I didn't receive got whatsoever stubborn bolts.
You mightiness desire to start past times trying to bust the driveaxle together with driveshaft bolts unloose first. These volition in all likelihood live the toughest bolts to larn out. If you lot can't larn them out, there's no sense inward continuing, together with it would suck to receive got to pose everything dorsum together
1. striking it amongst a hammer a span times
2. If it rounds off inside, assay out pounding an allen chip into it.
3. You could assay out grinding a slot inward it, together with using a screwdriver.
4. Try Vise Grips
5. You'll uncovering that at that topographic point is a connector betwixt pairs of bolts. If it's the right bolt of the pair, you lot tin exercise this connector every bit a lever (assuming the left bolt is out of course)
Thus the article Best Audi A4 B5 A4 1.8Tq Clutch Replacement
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