Audi Workshop Service and Repair Manuals

Exploded view - clutch release mechanism

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Press tool -VW 454-

t	Torque wrench -V.A.G 1331-

t	-1-Internal puller -Kukko 21/5-

t	-4-Counter-support -Kukko 22/1-

t	Sealing grease -G 052 128 A1-

t	Copper grease -Z 381 351 TE-

t	Adhesive -AMV 195 KD1 01-

1 -	Clutch slave cylinder

q	Removing and installing on vehicles with 8-cylinder engine → Chapter

q	Removing and installing on vehicles with 6-cylinder TDI engine → Chapter

q	Do not operate clutch pedal after slave cylinder has been removed.

q	Follow correct procedure when bleeding → Chapter

q	Tighten bleeder valve to 4.5 Nm.

q	When installing, push in until the securing bolt can be fitted.

2 -	Hexagon socket head bolt, 23 Nm

q	Clutch slave cylinder to gearbox

q	Self-locking

q

Renew

3 -

Bracket

q	For pipe/hose assembly

q	Bolt to gearbox with clutch slave cylinder

q	Not fitted on all versions

4 -

Plunger

q	Lubricate end of plunger with copper grease -Z 381 351 TE-

5 -

O-ring

q	Always renew → Fig.

q	Lubricate with gear oil before installing

6 -

Oil seal

q	For input shaft

q	Removing → Fig.

q	Original dimension → Fig.

q	Installing → Fig.

q	Pack space between sealing lip and dust lip half full with sealing grease -G 052 128 A1-.

7 -	Guide sleeve

q	Removing and installing → Fig.

8 -	Clutch release lever

q	Removing and installing → Fig.

q	Before installing, lubricate area which makes contact with plunger of slave cylinder with copper grease -Z 381 351 TE-.

9 -	Release bearing

q	Do not wash out; wipe clean only

q	Renew bearing if noisy

q	Checking release bearing → Chapter

q	Retainer lugs on release bearing must engage in release lever

10 -	Bolt, 25 Nm

q	Self-locking

q	Always renew

11 -	Leaf spring

12 -	Bolt, 25 Nm

q

2x

q	Self-locking

q	Always renew

13 -	Retaining piece

q	For guide sleeve

q	Removing and installing → Fig.

14 -	Intermediate piece

q	Renew if damaged

15 -

Gearbox

Removing and installing clutch release lever Removing –  Slacken off bolt -1- and remove leaf spring -2-. –  Remove clutch release lever -3- together with release bearing. –  Disengage retaining tabs of release bearing at release lever. Installing –  Prior to installing clutch release lever, apply a thin coat of copper paste -Z 381 351 TE- to contact surface for plunger of clutch slave cylinder. –  Fit clutch release lever -3- together with release bearing onto guide sleeve. –  Insert leaf spring -2- and tighten new bolt -1- to 25 Nm.

Removing and installing guide sleeve Removing –  Unscrew bolts -arrows- and remove retaining piece -1-. –  Fit a thin insulating hose or shrink hose tightly over splines of input shaft. –  Pull guide sleeve -2- over insulating hose and out of gearbox housing. Installing –  Renew O-ring in gearbox housing → Fig.. –  Pack space between sealing lip and dust lip with sealing grease -G 052 128 A1-. –  Lightly oil outer circumference of guide sleeve. –  Push guide sleeve -2- over input shaft and into gearbox housing. –  Remove insulating hose/shrink hose. –  Fit retaining piece -1-. –  Clean threads of bolts -arrows- with a wire brush. Then insert bolts with locking fluid -AMV 185 101 A1- and tighten to 24 Nm. –

Renew O-ring –  Pry out O-ring -arrow- using a small screwdriver. –  Lubricate new O-ring with gear oil before installing.

Pulling out input shaft oil seal A -  Counter-support -Kukko 22/1- B -  Internal puller -Kukko 21/5-

Original dimension - input shaft oil seal Dimension x = 7.75 mm ± 0.5 mm

Pressing in input shaft oil seal –  Lightly lubricate outer circumference of seal with gear oil. –  Press in input shaft oil seal → Fig. „Original dimension - input shaft oil seal“ (make sure oil seal remains straight). l  The open side of seal faces towards press tool -VW 454-. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.