This nice Audi came in with the concern of a slipping clutch. In fact the clutch seems to have failed in a very catastrophic way, with severe damage to the flywheel and pressure plate. The damage is so extensive that it is hard to determine exactly what did cause the failure, but my suspicion is the clutch release bearing hung up on the guide tube, keeping the clutch partially depressed and allowing slippage. After extended slippage, the heat build was great enough to cause the clutch friction material to fail and break apart.
I’ve seen this type of failure on the early Porsche 924S and 944 series, which uses a similar design. Correction entailed replacement of the flywheel – it is a fluid filled, dual mass type, the complete clutch, and the hydraulic actuating cylinder. With failures of this nature, it is important to always service as a system and replace all related components. For example, a sticking actuating cylinder, which disengages the clutch, can cause a repeat of the failure.
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| Audi A4 Quattro | Flywheel and Clutch assembly |
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| Clutch Pressure Plate – Note Heat Scoring | Audi Dual Mass Flywheel – Note Heat Damage |
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| Clutch Friction Disc | Clutch Overview, Bearing and Guide in Front |