Dismantling and assembling clutch "„E“" — AUDI

🧭 Before you start

Fits: Audi A4 Cabriolet B6/B7 (8H), Audi A4 B6/B7 (8E), Audi A8 D3 (4E, 2002–2010), Audi A6 C6 (4F, 2004–2011)

• Special tools named: T10285/1

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• When installing, make sure that circlip is seated securely all round in groove on cylinder "„E“".
• Mark exact contact point on cylinder "„E“".
• Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points.
• (Item 2) can be disregarded.

📋 Procedure

1. Detach circlip (1) and remove clutch pack (2) from cylinder "„E“".
2. Press retaining plate down using workshop press with assembly jig T10289.
3. Detach circlip (1).
4. Release workshop press.
5. Detach retaining plate (5).

6. Take out retaining plate (4) with O-ring (3).
7. Detach dished spring (2) from cylinder "„E“"(item 1).
8. Turn cylinder "„E“" upside down.
9. ⚠ Wear safety goggles. — Carefully press piston "„E“" out of cylinder "„E“" by applying compressed air (cover oil drilling on opposite side with your finger).
10. ⚠ Check components of clutch "„E“" for traces of wear and damage . — Renew O-rings (2) and (4) for piston "„E“"(item 3).
11. Push piston "„E“", (item 3) into cylinder "„E“", (item 1) as far as stop.
12. Fit dished spring (5).
13. Renew O-ring (6) in retaining plate (7).
14. Insert retaining plate (7).
15. Insert retaining plate (8).
16. Press retaining plate down using workshop press with assembly jig T10289.
17. ⚠ Take care not to stretch circlip too far when installing. — Renew circlip (1) and install new circlip with care.
18. When installing, make sure that circlip is seated securely all round in groove on cylinder "„E“".
19. Release workshop press.
20. Fit corrugated spring (2) in cylinder "„E“"(item 1).
21. Fit outer plates (3) and friction plates (4) alternately.
22. Insert thick outer plate (5).
23. Insert circlip (6).
24. Clamp support leg of compressor tool T10285 in vice.
25. Insert clutch "„E“" in compressor tool.
26. Position holding plate T40125 onto outer plate of clutch "„E“".
27. Fit centring pin of thrust piece T10285/1 into drilling in plate.
28. Bring clutch "„E“" into correct position on holding plate of compressor tool.
29. Turn spindle of compressor tool downwards.
30. Insert dial gaugeVAS 6080 into measuring bridgeVW 382/7 and secure with knurled nut.
31. Position measuring bridge on upper rim of cylinder "„E“" as shown in illustration.
32. Check that measuring bridge is seated properly on rim of cylinder "„E“".
33. Bring measuring tip into contact with outer plate and note value obtained.
34. Mark exact contact point on cylinder "„E“".
35. Repeat measurement at two other points on outer plate (offset by 120°) and mark measuring points.
36. Determine average value from the three measurements under load.
37. Release spindle and remove holding plate.
38. Use both hands to pull clutch pack upwards in clutch "„E“" as far as stop.
39. With clutch pack pulled up as far as stop, measure distance between upper rim of cylinder "„E“" and outer plate at one of the points marked (second mechanic required).
40. Repeat measurement at the two remaining markings on the outer plate.
41. Determine average value from the three measurements with clutch pack pulled up as far as stop.
42. Determine clearance using the following formula:
43. Subtract mean value of measurements with clutch pack pulled up as far as stop from mean value of measurements under load.
44. Determine new circlip (1). [Note: (Item 2) can be disregarded.]
45. Check clearance again after inserting circlip.

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