r/ManualTransmissions • u/Admirable-Answer-836 • 17h ago
VW/Audi 0A4 Manual Transmission
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Clutch drag and stiff/blocked gears after replacing DMF, Clutch, and Slave Cylinder
Hey everyone, I'm pulling my hair out trying to diagnose a persistent shifting issue on a VW/Audi 0A4 5-speed manual transmission and could really use some expert eyes.
Backstory & Replaced Parts:
Equipped with a VW 0A4 manual gearbox.
Parts Replaced: Dual-Mass Flywheel (DMF), Clutch kit (disc & pressure plate), (luk)and Hydraulic Slave Cylinder (luk) (concentric release bearing / butée hydraulique).
* **Bleeding:** The hydraulic system has been professionally bled. (But im gonna do another one in a couple of minutes to make sure)
**Current Symptoms:**
1. **With the engine off / at a standstill:** Gears are extremely stiff or completely blocked (especially 5th gear, though cable adjustments were already attempted).
2. **Clutch Drag:** When the car is in gear with the engine running and the clutch pedal is fully depressed, the car still creeps forward/backward.
3. **The Twist:** Once the car is actually rolling on the road, all gears shift are perfectly in place no noise but difficult to pass to another gear.
**What I've Checked So Far:**
* I am 100% confident the clutch disc was installed in the correct direction.
* I removed the starter motor to inspect the pressure plate and release bearing action visually.
I recorded a video through the starter aperture showing the slave cylinder/release bearing pressing against the clutch diaphragm when the pedal is depressed: slave moves and touches the diaphragm, but the release travel feels like it might be borderline or not fully unseating the disc.
Any advice would be hugely appreciated before I pull the whole gearbox back out!😭😭😭