Removing and installing clutch module: Audi A5 / A4 B8

🧭 Before you start

Remove the gearbox and fix it to the support, unbolt the left flange shaft bracket and withdraw the shaft keeping it centred. Fit the extractor and lift the clutch module off the input shaft. Grease the release bearing, clean the shaft and seal area, half-fill the seal lips with grease and lightly grease the input shaft splines. Slide the module on straight, then refit the flange shaft centred.

Fits: Audi A5 (8T, 2007–2016), Audi A4 B8 (8K, 2007–2015)

• Renewed: oil seals or needle bearing

Don't miss

• Keep the flange shaft centred going in and out, or its splines cut the differential oil seal.
• Support the bottom of the module while it comes off; it weighs about 20 kg and tilts easily.
• Never put the module down with the drive plate flange facing downwards; the flange bends.
• Wipe grease off the input shaft bearing journal before sliding the clutch module on.
• Renew the inner oil seal between differential and gearbox housing if it shows any damage.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Remove gearbox and secure to gearbox support T40173 using tensioning strap (1)6-speed manual gearbox 0B434Removing and installing gearbox; Removing gearbox.
2. Unscrew bolts (arrows) on mounting bracket for flange shaft (left-side).
3. Remove flange shaft from gearbox in direction of (arrow A). Keep shaft end (2) centred in opening on front final drive (arrow 3). [Note: If the flange shaft (left-side) cannot be removed by hand, pull it out carefully using multi-purpose toolVW 771.]
4. ⚠ Risk of damage to oil seal.If you do not keep the shaft centred when pulling it out further, the splines of the shaft (2) will fall against the inner oil seal (arrow 3) between the differential and the gearbox housing.If oil seal is damaged, it must be renewed . — To do this, secure plate of puller T10037 to flange shaft (arrows) and attach plate to spindle of multi-purpose toolVW 771 (nuts (A)).
5. Attach extractor T40176 to clutch module (A) using nut (B)(arrow).

6. Turn extractor T40176 upwards.
7. ⚠ Risk of damage to oil seals and needle bearing in dual-mass flywheel.The clutch module weighs approx. 20 kg.Keep firm hold of the bottom of the clutch module, as shown in the illustration, to prevent the clutch module from tilting over.When removing and installing the clutch module, take care not to damage the oil seals and needle bearing in the dual-mass flywheel (arrow).Renew oil seals or needle bearing if damaged . — Pull clutch module off input shaft (arrow) keeping clutch module straight.
8. ⚠ Take care not to damage flange for drive plate on dual-mass flywheel.Do not put down clutch module with flange (arrow) for drive plate facing downwards.This could bend the flange (arrow) for the drive plate, which would cause problems with clutch operation. — Put clutch module down carefully, e.g. on work bench, with pressure plate facing downwards.
9. Grease clutch release bearing according to specifications .
10. Thoroughly clean flange shaft (left-side), area of gearbox housing leading to differential (arrow A) and oil seal (arrow B). [Note: If oil seal between differential and gearbox housing (arrow B) is damaged, it must be renewed .]
11. Pack space between sealing lip and dust lip (arrow B) half full with sealing greaseG 052 128 A1.
12. Clean input shaft (arrow).
13. Apply a thin coating of grease for clutch plate splinesG 000 100 to splines on input shaft.
14. ⚠ Before installing clutch module, remove grease from input shaft bearing journal (arrow) as far as splines. — Carefully slide clutch module onto input shaft taking care to keep clutch module straight.
15. Detach extractor T40176 from clutch module.
16. Turn clutch module (1) so that you can see opening to differential (arrow 3).
17. Slide flange shaft (left-side) into gearbox in direction of (arrow B) (keep end of shaft (2) centred while guiding it into oil seal on final drive (arrow 3)).
18. ⚠ Risk of damage to oil seal.If you do not keep the shaft centred, the splines of the shaft (2) will damage the oil seal (arrow 3) between the differential and the gearbox housing.If oil seal is damaged, it must be renewed . — Tighten flange shaft mounting bracket (arrows). Tightening torque

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