Clutch Problems AVF: Find a Permanent Solution

Hello everyone,

Unfortunately, I've had a different software installed on my 1.9 PD AVF engine with 415 Nm for the last 30,000 km, and since then, the clutch has been slipping... sometimes more, sometimes less, and sometimes not at all.
I'm surprised it even manages to get going. As I said, it usually only slips in 5th and 6th gear when I want to accelerate more forcefully uphill on the highway.

Even when downshifting from 2nd to 1st gear, you can now hear a loud knocking sound.
I suspect the ZMS is now signing off.

Now I need to replace the clutch, and I'm considering switching to the Valeo 4K kit.
I've now spent 10 hours online and have occasionally read that the kit fails after about 20,000 km.

Now the question is whether anyone here has experience with the Valeo 4K kit...

The following kit would be suitable for my vehicle:
My vehicle:

A4 B6, year 2002, 1.9 AVF engine, 185,000 km (approx. 115,000 miles), primarily highway miles.

Clutch kit + flywheel VALEO - Ref.: 835026
VALEO 4KKIT
Diameter 1 [mm]: 240.9
Technical Information Kit 4P (3-component kit + rigid flywheel).
Version DBR
Diameter 2 [mm] 240.
Number of teeth: 23.
Hub profile 21.8.
Hub profile 24.3.
with flywheel


Price-wise, it's quite interesting, as you can find it online for just €380.
http://www.autoteilemann.de/kupplungssatz-vw-553391.html

The original LUK kit, including the flywheel, would cost approximately €520.
http://www.profiteile.de/index.php/product/600+0040+00/6/luk-kupplungssatz

I hope someone can help me with this decision.

Hmm, it seems like it's difficult to find replacement parts for this series.

Look at this: https://community.dieselschrauber.org/en/viewtopic.php?t=14189&highlight=sachs+racing

Unfortunately, that doesn't help me much because it refers to the Sachs clutch.

The question is whether anyone has already installed the 4K kit and has used it for 20-30,000 km, and whether it's any good. If it's not good, I'll switch to the OEM kit, including the LUK clutch and dual-mass flywheel.

Well, for series motors, Valeo should work - call for 415 Nm.


Valeo Service Germany GmbH
46 Brandenburger Straße.
40880 Ratingen.
Tel.: (+49) 21 02 865 0
Fax: (+49) 21 02 865 142

Thank you for the information. I had already called there and spoken with a knowledgeable technician.
But of course, they also just want to sell their products.
He said everything was great except for a humming noise that occurs during acceleration between 1600 and 2000 RPM.

I'm more interested in long-term experiences because I don't plan on replacing the clutch after only 20,000 kilometers.
Because I had found this information online twice already.
But usually only people who have a problem with something will respond, which is why I'm asking if anyone has had good experiences with the 4K kit...

Kitwing wrote:

Unfortunately, I've had a different software on my 1.9 PD AVF with 415 Nm for the last 30,000 km, and since then, the clutch has been slipping...

Have you ever considered lowering the torque peak of the software to a wider plateau of around 370-380 Nm? It only costs a little driving pleasure, but it significantly reduces the strain on the hardware. }

Yes, I had considered that too... but given my driving style, I rarely reach that torque range, so I actually wanted to leave it as it is.

But it's not a peak; rather, it extends very evenly over 300 revolutions before slowly decreasing.

Well, I think I wanted it that way too... The software is from F** A****, whom I know quite well, and he immediately asked me if I wanted something more... Then he put something specific together for me... As a result, we ended up with 415 Nm back then.
He immediately said that the OEM clutch wouldn't last more than 5,000 kilometers.

Hmmm, it looks like I'll probably end up buying the 4K kit from Valeo and then providing a long-term review here.
I don't have a high opinion of Sachs clutches.


EDIT by DBär: Please, no names or advertising.

Okay, I wanted to let you know what my impressions are of the Valeo kit.

Currently, I've driven the kit for 11,000 km, and I have to admit that it makes a bit of a rumbling noise at low RPM, around 1300-2000 RPM.
It feels a bit rougher than the original.
But otherwise, I couldn't really notice a significant difference.
It handles the torque very well.
The clutch pedal feels slightly harder to press than it used to.