VW Passat 1.8T Clutch Kit 02-027 for Audi A4 1997-2005

A complete clutch replacement set for the longitudinal-engine 1.8L turbo cars: the 1998-2005 Volkswagen Passat and the 1997-2005 Audi A4 and A4 Quattro with a manual transmission. It crosses to the common 02-027 and 02-028 kit numbers. In the box: the pressure plate, a sprung clutch disc, the release (throwout) bearing, a pilot bearing, an alignment tool and a grease packet.

Measure before you commit: pressure plate about 10.37 inches, disc about 8.98 inches across with a 23-spline hub, input shaft about 0.96 inch. If your old disc does not match those numbers, stop and confirm the application before going further.

Typical reasons to do the job: slipping in fourth or fifth under boost, an engagement point that has crept to the top of the pedal, shudder pulling away from a stop, or a chirp or growl from the release bearing with the pedal down. These cars run a dual-mass flywheel from the factory. With the transmission out, check the flywheel for heat spots, cracks and excessive free play or rattle; a worn dual-mass flywheel will chatter and eat a new clutch, so replace it rather than reuse it if it is out of spec.

On reassembly, center the disc with the alignment tool, run the pressure plate bolts down in a star pattern to spec, and use a thin film of grease on the input shaft splines and release bearing guide. An oil-soaked old disc points to a leaking rear main or input shaft seal. Fix that first or the new disc will slip the same way.