Audi Workshop Service and Repair Manuals

Removing

Note:

By way of example, removal is described in the following for a vehicle with V6 TDI engine.

• ‒ → Remove rear section -D- of noise insulation.

• ‒ → Slacken off bolt -2- of noise insulation over left drive shaft.
• ‒ Disengage hook -1- and detach noise insulation.

• ‒ → Unscrew left drive shaft -A- from gearbox and lay it aside.
• ‒ Detach heat shield -B- from gearbox.
• ‒ Remove left gearbox support -C- complete with gearbox mounting. To do so, screw out bolts -arrows-.

• ‒ → Screw out bolt -arrow- and pull out clutch slave cylinder to rear.

Note:

Do not press clutch pedal after removing slave cylinder.

• ‒ → To remove pipe, prise out clip -A- as far as detent using a screwdriver. Pipe can then be pulled out.

Installing

Install in reverse order, paying attention to the following:

Notes:

• ◆ Brake fluid must not be allowed to come into contact with gearbox. Clean gearbox housing if necessary.
• ◆ Tilting clutch slave cylinder on insertion could cause plunger to move past clutch release lever.
• ◆ To facilitate assembly, engage 6th gear before fitting slave cylinder.
• ◆ Pretension clutch slave cylinder such that bolt can easily be inserted.
• ◆ Always replace bolt.

• ‒ → Press in clip -A- as far as it will go to connect pipe to slave cylinder.
• ‒ Insert pipe -B- in slave cylinder until it is heard to engage.

• ‒ → Before installing slave cylinder in gearbox housing, area -a- of boot must be coated with lithium grease G 052 150 A2.
• ‒ Apply thin coat of copper grease, e.g. Z 381 351 TE, to contact surface for plunger at clutch release lever.

• ‒ → Engage holder for hose/pipe assembly -3- at slave cylinder -4-.

• ‒ → Guide clutch slave cylinder into mounting hole of gearbox housing without any major lateral deviation from operating direction of plunger and screw on -arrow-.
• ‒ If pipe has been disconnected at slave cylinder, clutch system must be bled after installing slave cylinder.

• ‒ → Install gearbox support -C- with gearbox mounting.
• ‒ Screw drive shaft -A- to flange shaft.

=> Running Gear, Front-wheel Drive and Four-wheel Drive; Repair Group 40

• ‒ Screw heat shield -B- to gearbox.

Tightening torques

    1)    Replace bolt