Clutch Clinic: Audi A3 2.0 TDI

We fit a new clutch and dual mass fly­wheel to our ex-project Audi.

Car Mechanics (UK) - - Contents -

Re­new­ing the clutch, re­lease bear­ing and dual mass fly­wheel (DMF) on a 2005 Audi A3 2.0 BKD diesel en­gine takes three to four hours, as­sum­ing you have ac­cess to a two-post ramp and all the nec­es­sary tools (see Es­sen­tial Tools).

The work in­volved isn’t par­tic­u­larly dif­fi­cult, but the gear­box is heavy to lift, so we rec­om­mend you re­cruit three helpers to re­move and re­fit it. Space is tight when ma­noeu­vring the gear­box in and out of the en­gine bay, so it’s tempt­ing to de­tach the off­side drive­shaft cou­pling, but this will inevitably re­sult in gear­box oil leak­ing out. The gear­box can be drained, but this re­quires a spe­cial 16mm multi-splined tool with a hole in the cen­tre to undo the drain plug, which has a notch in the mid­dle. We cov­ered this sub­ject in more depth in the June 2016 is­sue, re­new­ing the gear­box oil with two litres of 75W GL-4 oil.

Other is­sues can eas­ily arise when un­der­tak­ing this work, such as split CV boots and leak­ing drive­shaft seals, all of which we cov­ered in our A3 project car se­ries from April-oc­to­ber 2016.

The fol­low­ing steps show the clutch, DMF and re­lease bear­ing be­ing re­newed for the A3’s six-speed man­ual gear­box us­ing a Sachs kit sup­plied by GSF Car Parts. One of the main dif­fer­ences be­tween this and the five-speed man­ual gear­box is that the clutch and DMF are of­ten sup­plied pre-as­sem­bled on the five-speed, whereas they are sep­a­rate units on the six-speed.

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