Adjusting clutch engagement mechanism (gearbox manufacturing date up to 05.2011) — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012), Audi TT Mk2 (8J, 2006–2014), Audi A1 (8X, 2010–2018), Audi A3 (8V, 2012–2020); platform codes FV, 85

• Special tools named: VAS 6594

Don't miss

• A very small number of earlier gearboxes do not have this clip.
• Do not perform measurement at gap in circlip; otherwise the circlip could be pressed out of position and the measurement would be incorrect.
• Place gauge block T10374 on large engagement bearing; large opening must face downwards.
• To make sure that gauge block T10374 is seated correctly on engagement bearing, press down on gauge block and turn it.
• Risk of incorrect measurements.The ruler T40100 should remain in this position during the following measurements - do not change its position or remove it. — Set depth gauge to "“0”".

📋 Procedure

1. ⚠ Risk of damage to the clutch and other components!The support bearing for the engaging levers and all the mechanical components of the engagement bearings must be dry and free from oil and grease. — Insert support bearing for engaging levers.
2. Install small engaging lever with clip and secure with two new bolts. [Note: A very small number of earlier gearboxes do not have this clip.]
3. Insert large engaging lever.
4. Check that both engaging levers are seated correctly.
5. Re-install old circlip on outer input shaft.

6. Place ruler T40100 on edge across gearbox flange above end of shaft.
7. ⚠ Risk of incorrect measurements.The ruler T40100 should remain in this position during the following measurements - do not change its position or remove it. — Set digital depth gauge (300 mm)VAS 6594 on top of ruler T40100 and apply tip of depth gauge to outer input shaft.
8. Set depth gauge to "“0”".
9. Apply tip of depth gauge to circlip, as shown in illustration.
10. Determine dimension "“B"1” to circlip at this point.
11. Determine dimension "“B"2” to circlip on opposite side. [Note: Do not perform measurement at gap in circlip; otherwise the circlip could be pressed out of position and the measurement would be incorrect.]
12. Calculate mean value of dimensions "“B"1” and "“B"2”.
13. Remove and dispose of circlip.
14. Place gauge block T10374 on large engagement bearing; large opening must face downwards.
15. To make sure that gauge block T10374 is seated correctly on engagement bearing, press down on gauge block and turn it.
16. Set digital depth gauge (300 mm)VAS 6594 on top of ruler and apply tip of depth gauge to outer input shaft.
17. ⚠ Risk of incorrect measurements.The ruler T40100 should remain in this position during the following measurements - do not change its position or remove it. — Set depth gauge to "“0”".
18. Apply tip of depth gauge to gauge block T10374, as shown in illustration.
19. Determine dimension "“A 1"a” to gauge block T10374 at this point.
20. Determine dimension "“A 1"b” to gauge block T10374 on opposite side.
21. Calculate mean value of dimensions "“A 1"a” and "“A 1"b”. [Note: The actual depth of the engagement bearing for clutch "“K 1”" must now be calculated from dimensions "“A 1”" and "“B”" as follows:] [Note: The clearance of clutch "“K 1”" must now be calculated from the actual depth and the specified depth of the engagement bearing as follows:]
22. Read tolerance value for clutch off new clutch. [Note: The thickness of shim "“SK 1”" must now be determined from the values for the clearance and the tolerance of clutch "“K 1”" as follows:]
23. Measure and select required shim from shims supplied and have to hand for installation.
24. ⚠ Risk of damage to gearboxMark shim as "“SK 1”" and have this shim ready for assembly.This shim "“SK 1”" (and only this shim) must be fitted when adjusting. — Only insert small engagement bearing.
25. Check that small engagement bearing is installed correctly and grooves are seated properly by turning it (arrows).
26. Place gauge block T10374 on small engagement bearing; large opening must face upwards.
27. Set digital depth gauge (300 mm)VAS 6594 on top of ruler and apply tip of depth gauge to outer input shaft.
28. ⚠ Risk of incorrect measurements.The ruler T40100 should remain in this position during the following measurements - do not change its position or remove it. — Set depth gauge to "“0”".
29. Apply tip of depth gauge to gauge block T10374, as shown in illustration.
30. Determine dimension "“A 2"a” to gauge block T10374 at this point.
31. Determine dimension "“A 2"b” to gauge block T10374 on opposite side.
32. Calculate mean value of dimensions "“A 2"a” and "“A 2"b”. [Note: The actual depth of the engagement bearing for clutch "“K 2”" must now be calculated from dimensions "“A 2”" and "“B”" as follows:] [Note: The clearance of clutch "“K 2”" must now be calculated from the actual depth and the specified depth of the engagement bearing as follows:]
33. Read tolerance value for clutch off new clutch. [Note: The thickness of shim "“SK 2”" must now be determined from the values for the clearance and the tolerance of clutch "“K 2”" as follows:]
34. Measure and select required shim from shims supplied and have to hand for installation.
35. ⚠ Risk of damage to gearboxMark shim as "“SK 2”" and have this shim ready for assembly.This shim "“SK 2”" (and only this shim) must be fitted when adjusting. — Install dual clutch .

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