A2 1.4 TDi 90PS ATL clutch and DMF change

A2 1.4 TDi 90PS ATL clutch and DMF change.

So the clutch gave up, pedal pumps bit easier than usual, but clutch stays engaged -> Gears can be put on w/o pressing clutch.

Only symptom I got was bit of disengaging problems when the temperature was below -20C (2-hand gear selection needed, but the gear selector on engine bay was movable by hand). Read about similar problems here so it wasn't a real surprise, funny that the problem just first went away and then the clutch just stayed engaged when it broke. It seems that after the car sat for a day the clutch re-engaged itself a bit as the gear change couldn't be done to all gears w/o pressing the clutch, after which it stayed on again. No fault codes via VCDS.

So I am guessing it can't be the master/slave cylinder because no visible fluid, and the clutch isn't returning to engaged position so it would be the pressure setting, the clutch surface or clutch bearing problem.
Taking into account that my DMF was making clunk sound every now and then, I'm going to have it changed too when the box is coming out.

Looking to make a parts list now to make sure everything gets changed that can be. I'm guessing it would be safe to change the slave cylinder at the same time but any advice is welcome.

Sorry for the bad English in the parts names.

Update: I changed the unknown numbers to new numbers, and divided the list with "*" markers per part

Parts list:
* Pressure plate + Friction surface ("clutch") + Dual-Mass-Flywheel (DMF) [size 225mm]
- Set: Audi: 045 105 264 B (1050eur) is equal to LUK kit 417 0047 10

- Only manufacturer for A2 is LUK so same parts w/o Audi logos. Note that Audi shows that release bearing belongs to the set, LUK doesn't.
- LUK kit includes also: Bolts for clutch assembly (12pcs) = Audi: N 907 255 01 (M6x16) (0,5eur/ea)
- LUK kit includes also - N 906 650 01 x 6 (2,5eur ea) for mounting the DMF
- LUK kit price point (2012/2013) is around 500-600 euros

* Clutch release bearing = Audi: 02A 141 165 M (Old number was 02A 141 165 A)
- 40-60 euros from Audi
- 15-20 euros as Sachs/LUK part

Other parts you want to change when gearbox is removed
* Release lever(?) = Audi: 02J 141 719 C (20 eur)
* Spring for lever = Audi: 012 141 741 (2eur)
* Guide bush(?) + gasket = Audi: 02A 141 180 A (20 eur)
* Bolts for guide bush (3pcs, M7x14) = Audi: N 903 544 05 (2eur) (Old number: N 903 544 04)
* Ball joint = Audi: 02A 141 777 (6 eur)

Optional replacement
* Clutch slave cylinder = Audi: 6Q0 721 261 E (40eur)

Work at garage
- Around 7,5h - 8,5h
- Will probably need to replace driveshaft attachment bolt and some nut but should be common inventory

luk_dmf_set_back.jpg
luk_dmf_set_front.jpg
misc_parts.jpg
 
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Thanks chubbybrown for the clutch link but I couldn't find the DMF sold solo, only the LUK kit with the clutch, same as the one offered by audi.
For the SMF, I didn't find any proven solution off the shelf from forums, so I think the easiest route is to go with the DMF and be happy with less torque stress on the gearbox.

Spike, yeah that sounds like an option but I doubt the flakey coating could hold the fluids for 1h+.
 
There is a thread here about smf, but I couldn't agree with it the same as your self.
I went for a new clutch and DMF myself.
its not cheap though :-(

If you cant find thread say back here and I will have a look for it.
 
I've read the threads on this forum about clutch problems/DMF conversions to SMF/gearbox problems but I do not remember anyone actually doing DMF>SMF on ATL. As the DMF is the #1 choice for from the pricepoint at the moment (ie. DMF will cost ~ same as SMF from one of the sellers on ebay or the UK garages shops mentioned but not one of these are 101% fit as I know and will mean more money for the garage and more time w/o the car) I think I'll order the LUK set and check what it holds and then order rest of the parts. Any help is welcome ofc if someone remembers otherwise.

Found two good threads (1 and 2) from the German forums which tell that the LUK set would include: Friction plate + DMF + Pressure setting + 12 bolts. And also seems to contain the same parts I had listed.
 
Fixed

New DMF set went in and working like a charm, needed few bolts and a nut/washer for driveshaft mounting. Work time was 8 hours.

Reason for fault was the DMF, it caused stress from them bumping motion (as the springs we depleted etc) to the friction plate/disc and the base had torn off from the outer edge.

Will post pics when I remember to visit next time.
 
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Nice one.
Mine had to be replaced as it had seized flywheel-clutch after me thinking car could swim,Damn nearly hydrolocked the engine
 
Added pics of new parts to first post and here are the old ones.
DMF was movable my hand / few fingers from side to side. Doubt though that it would've broken anytime soon - so could've driven with the clanky DMF untill something else would've started to make sound. It only made sound when applying gas fast, so it wasn't making constant noise nor banging sound on hitting each max point. But I guess the clutch plate could be the weak point of the system(?), just my two pennies.
old_clutch_plate.jpg old_clutch_plate_2.jpg
old_dmf_movement.jpg old_dmf_package.jpg
old_dmf_surface_flash.jpg old_pressure_plate.jpg
 
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When I left the garage my meter rolled to 115000km, 2004 model. But I am guessing that it has had daily driving before me and short trips. No idea how long the DMF had been making noise.
 
Dadomonster - did you change it yourself, if so how was it, any specialist tools required? Mines done 90000m (144000km) was thinking of having a go myself when it goes, no noises at the moment though thanks goodness :)
 
Was done by garage, its about 8h job if you know what you are doing. No specialist tools needed, just need to drop the gearbox and switch parts.
 
hi
same problem here so i i asked this seller for this SMF kit http://www.befr.ebay.be/itm/250943679853?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649
he say it will fit my 2005 A2 90 (ATL)
so i ordered it mountit with in Midas Garage (i dont know if it exist also in UK ?)
but when finished work we got 2 problem clutch paddle is hard to press and no way to change gear !! a part when motor is off i can change gear
it seem like u press half way on clutch .
so i contact him and reply my that its need bleeding as it new....
and my garage say it not the good part....
 
hi
done the conversion from dmf to smf but not working i bought a kit on ebay seller tell me its an conversion kit to smf but doesnt work (cant engage gears)

item number on ebay : 250943679853
 
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