Best Audi Tt A4 1.8Tq Clutch Replacement
Title : Best Audi Tt A4 1.8Tq Clutch Replacement
link : Best Audi Tt A4 1.8Tq Clutch Replacement
Best Audi Tt A4 1.8Tq Clutch Replacement
DISCLAIMER: This data is presented simply every bit a guide. Due to changes from year-to-year in addition to options-to-options it may non live totally accurate. I tin dismiss non live held responsible for anything that happens every bit a number of using this guide.
This is non something that should live attempted yesteryear soul who has never worked on a car, or has lilliputian sense alongside them.
If y'all utilization this guide, I solely inquire 2 things:
1. Accept the disclaimer,
2. Provide Feedback - comments/tips/problems/differences.
There, at ane time 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, in addition to has an angle adjuster in addition to strap to proceed 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 touching 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 fleck - special tool???
- Loc-Tite
- Patience
- Common Sense
- fan (gotta proceed cool, right?)
If you're planning on changing the trans fluid, at that spot are some special tools required. On my machine it required a 17mm allen wrench (fill plug) in addition to "3357 triple foursquare socket" (drain plug) I bought the 3357 from http://www.zelenda.com in addition to made the allen from a 17mm bolt welded to an one-time 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 upwardly plug remover yesteryear welding a nut to bolt, in addition to using a wrench on the nut, which turned the bolt, which turned the fill upwardly plug. I in addition to then picked the trans upwardly in addition to drained it through the fill upwardly plug. I used Redline MTL (75w90) fluid, it takes 2.9 quarts.
If y'all create alter the fluid, create it after you're done. Wouldn't desire to receive got the jeopardy of spilling fluid inward the surface area y'all volition live working in/on for the adjacent 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 y'all muck upwardly the ones y'all have.
- New lock-nuts for the turbo - Bentley manual says to supplant them, I didn't
- New drive axle in addition to driveshaft seals - Bentley manual says to supplant them, I didn't
Instructions - Removal
I am next the Bentley manual for the most part. There are some steps I skipped, some that involve to live added, in addition to others that tin dismiss live done differently. I'm posting the steps in addition to providing to a greater extent than information alongside them. If y'all are attempting this, y'all should receive got this manual already. It contains many other things, peculiarly the required torque values for the bolts.
1. Disconnect set down cable from battery - 10mm
2. Remove driveshaft - ignore this step, it's non necessary
3. Remove airbox - run into pic
- Disconnect MAF connector
- Disconnect Power Output Stage connectors (see moving painting - 1)
- Disconnect Solenoid Valve for Wastegate Bypass Regulator Valve connector (see moving painting - 2)
- Disconnect EVAP canister purge regulator valve connector (see moving painting - 3)
- Disconnect hoses
- Pull airbox out
My machine has a custom cone air setup, which is why the POS is mounted on aluminum in addition to bolted to the fender.
4. Remove coolant tank in addition to laid aside
- take 3 screws from top (phillips)
- Lift upwardly in addition to disconnect sensor from bottom (careful)
- take top coolant line in addition to plug.
- Leaving the bottom hose (big hose) connected, rotate the tank around close 135 degrees in addition to lay it down
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| Coolant tank sitting seat in addition to O2 sensor connectors. |
5. Disconnect minute O2 sensor connector from nether the coolant tank (leftmost connector - run into pic) in addition to gratis the wiring from whatever ties.
6. Remove O2 sensors. The manual does non nation to create this, but I did it. Trying to take the truthful cat is hard plenty without having to worry close breaking the O2 sensors too. Takes a 22mm wrench in addition to a lilliputian elbow grease. You'll in all likelihood receive got to runway downwards the connector for the master copy O2 sensor, or y'all mightiness perhaps twist the wires plenty to intermission 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 upwardly inward handy for the bottom nut.
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| The nuts in addition to O2 sensor receive got been removed |
8. Remove trans-to-engine bolts that y'all tin dismiss larn to from above. I intend at that spot were 3 accessible from to a higher house (left, middle, in addition to right) 16mm.
9. Remove engine pan/cover from underneath - 10 screws: 3 front, 3 back, 2 inward each bike well.
10. Remove bracket for engine pan/cover - 2 bolts (13mm I think)
11. Jack machine upwardly in addition to lay on jack stands. I'm non actually for certain of a adept house to lay the jackstands, I at ane time receive got 2 slight dents inward the floorboard of my car.
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| Car upwardly inward the air. Possibly bad spot for jack stands. |
12. Remove heatshield from rider side drive axle. Three 6mm allen bolts, 2 accessible alongside an allen socket (left in addition to right) in addition to the top bolt requires an allen wrench.
13. With the machine supported on jack stands, house slight pressure level on the trans alongside a jack.
14. Unbolt rider side mount/support (leave mountain connected to support) - 2 13mm bolts, in addition to 3 8mm, again, 2 accessible alongside an allen socket (left in addition to right) in addition to the top bolt requires an allen wrench. Also take the saltation mountain from the downpipe. You tin dismiss permit 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, in addition to ended upwardly pulling the downpipe out of it instead.
16. Remove the cat/downpipe yesteryear pulling it out from nether the car. I made the fault of trying to larn it out from the top. I did finally larn it alongside a lot of swearing in addition to fidgeting. Oh well.
 |
| Catalytic converter in addition to downpipe |
17. Remove RPM sensor from transmission. My machine did non receive got this. If it did, it would live located on the driver's side of the transmission, to a higher house the flywheel (about the 2 o'clock seat if looking at the forepart of the trans).
18. Now the fun utilization (1st of many) Disconnect the driveaxles. The shafts are bolted inward alongside 6 12 betoken torx-head bolts. I was able to utilization a regular 6point T-40 torx fleck to take them, but I highly recommend trying to larn the 12 betoken fleck to cut the jeopardy of rounding ane of these things off.
19. Disconnect Speed sensor in addition to contrary low-cal connectors on driver's side of the trans. Make for certain no other connectors are attached.
20. Remove starter, 2 16mm bolts in addition to ane 6mm allen bolt. The wires tin dismiss rest connected. This tin dismiss live done ane of 2 ways: The long in addition to painful way, or the brusk in addition to 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 alongside an allen wrench yesteryear maneuvering your manus in addition to arm through the A/C lines. When finally out (wait until y'all receive got to lay it dorsum in) take the 2 starter bolts, slide the starter forwards in addition to sweat 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 utilization of an allen wrench. When it's out to the betoken that the allen wrench hits the trans tunnel, take the allen wrench in addition to examine turning the bolt or washer on the backside alongside your fingers.
23. Remove the oestrus shield for the driveshaft. My machine did non receive got this.
24. Remove the driveshaft from the trans - 6 T-40 Torx bits, permit it hang on the oestrus shield.
25. Remove the iv engine-to-trans bolts on the bottom (all 16mm), in addition to at that spot should live exactly 2 left belongings it together afterwards.
26. Place transmission jack nether the trans in addition to lay pressure level on it.
27. Remove driver's side trans mount-to-support bolt (8mm allen bolt), leave of absence the back upwardly bolted to the trans.
28. Remove the lastly 2 engine-to-trans bolts.
29. slide trans in addition to 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 alongside a 6mm allen bolt, in addition to volition receive got a lilliputian fleck of wiggling to larn it out. Careful, it's made of plastic. Do NOT take the line, in addition to create NOT press the clutch pedal.
31. Make for certain all drive axles are clear of the trans in addition to lower it. You mightiness receive got to describe the trans off the jack to slide/drag it out from nether the car, or y'all tin dismiss exactly leave of absence it nether the car, in addition to slide it out of the way.
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| Empty trans tunnel. |
 |
| Parts removed |
1 - Passenger side trans mountain in addition to related bolts
2 - Exhaust clamp bolts
3 - Passenger side drive axle shield in addition to related bolts
4 - Starter Bolts
five - Engine-to-Trans bolts
6 - Turbo-to-downpipe nuts
vii - 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
thirteen - Just a rag, ignore it :)
Removing the clutch/flywheel
1. Remove the 6 6mm allen caput bolts from the pressure level plate in addition to take it in addition to the clutch plate. H5N1 screwdriver mightiness live needed to gently pry it off. Careful, the pressure level plate is the solely affair belongings the clutch plate in, in addition to it WILL autumn if you're non paying attention.
2. Bust out the touching on wrench to loosen the 6 17mm flywheel bolts. You in all likelihood don't involve the impact, but y'all volition pass a really long fourth dimension trying to larn the bolts publish without one.
Installing the clutch/flywheel
1. Look at the flywheel in addition to you'll honor the bolt holes are irregular. The flywheel solely goes on ane way. when y'all receive got all 6 bolts in, torque them down. I held a screwdriver betwixt a flywheel molar in addition to 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 score turn. Check alongside APR to live sure.
2. Put the clutch disk in addition to pressure level plate on, the clutch disk has to larn inward a for certain agency (the taller middle side goes towards the pressure level plate) Start putting the bolts in, but don't tighten yet. You involve 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, close vii hours.
Take a break, the hardest utilization is close to begin.....
1. With the transmission on the transjack (if it has an angle adjuster, brand for certain it's on the right side), slow elevator it into place, making for certain that zip is inward it's way. You volition involve to tally the angle of the engine alongside 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 aid to receive got a greater angle on the trans, in addition to 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 - honor the the dents from the jackstands. |
2. Put the clutch slave cylinder dorsum on. Trust me on this one, create it now, earlier the trans is connected.
3. Now the fun part, inserting the trans. Mine slid right in, but if it doesn't, shout out upwardly patience is the key. Put the trans inward gear in addition to examine rotating the driveshaft end. this rotates the input shaft, in addition to may aid align it. If all else fails, describe the trans out (careful if the slave cylinder is bolted on), in addition to banking firm check to brand for certain the clutch is notwithstanding centered.
4. The trans in all likelihood wont slide all the agency in. Get it inward plenty to larn a bolt started on either side (start alongside the bolts that larn through the guide pins.
5. Basically, everything else is the opposite of removal, exactly a lilliputian to a greater extent than difficult.
Reassembly time, close 8 hours.
Things to avoid (aka what I did wrong)
1. Remove the cat/downpipe from the bottom. It volition come upwardly out from the top alongside a lot of struggling, yanking, in addition to cursing, or it volition drib right out the bottom alongside slight maneuvering.
2. when putting the transmission in, I got the shifter pin arm caught betwixt the trans in addition to the hull, in addition to bent it straight. I establish this out after I had everything in, in addition to realized I couldn't shift into 1st, 3rd, or 5th. The shift rod wouldn't come upwardly dorsum far plenty because it striking the shifter pin arm. H5N1 jack in addition to a 2ft long 2x4 promptly bent the arm dorsum into sort :)
3. I tried to lay the clutch slave cylinder on after the trans was installed. I could non larn it to compress plenty to install. I had to crevice opened upwardly the bleed screw in addition to and then force it inward (I had a hose in addition to container hooked upwardly to grab the fluid), in addition to and then bled the clutch arrangement later (not a large bargain though)
4. My APR flywheel/clutch was used in addition to didn't receive got whatever bolts alongside it. I had to cutting 5/8" off the terminate of the flywheel bolts inward fellowship to utilization them.
Notes/Comments/Suggestions:
Plan on a weekend for this job. Start Fri night, in addition to if all goes well, y'all should live done Sabbatum night, or Dominicus morning.
I started Th nighttime close 10pm, worked until the trans was out at 4am. I started over again Fri nighttime close 9pm, worked until 4am in addition to finished upwardly a twosome lilliputian things Sabbatum afternoon.
I should also nation that my clutch in addition to centre Torsion were replaced close 10 months agone (25K miles) hence I didn't receive got whatever stubborn bolts.
You mightiness desire to start yesteryear trying to bust the driveaxle in addition to driveshaft bolts publish first. These volition in all likelihood live the toughest bolts to larn out. If y'all can't larn them out, there's no sense inward continuing, in addition to it would suck to receive got to lay everything dorsum together
1. striking it alongside a hammer a twosome times
2. If it rounds off inside, examine pounding an allen fleck into it.
3. You could examine grinding a slot inward it, in addition to using a screwdriver.
4. Try Vise Grips
5. You'll honor that at that spot is a connector betwixt pairs of bolts. If it's the right bolt of the pair, y'all tin dismiss utilization this connector every bit a lever (assuming the left bolt is out of course)
Thus the article Best Audi Tt A4 1.8Tq Clutch Replacement
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