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Removing and installing clutch slave cylinder > < Servicing clutch release mechanism

A4 Mk2

Clutch release mechanism - exploded view
   
Clutch release mechanism - exploded view
1 - Gearbox
2 - Ball head stud
q   25 Nm
q   Lubricate with MoS2 grease
3 - Intermediate piece
4 - Dished spring
q   Smaller diameter (convex side) faces guide sleeve
5 - O-ring
q   Renew
6 - Input shaft oil seal
q   Available as replacement part together with guide sleeve → Item
q   Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.
7 - Guide sleeve
q   Available as replacement part together with oil seal → Item
q   Installation position: Oil drain hole points downwards
q   Before removing and installing, cover input shaft splines with a shrink-fit hose to protect oil seal → Item
8 - Retaining spring
q   Secure to clutch release lever
9 - Torx socket head bolt
q   35 Nm
q   Self-locking
q   Always renew
10 - Clutch release lever
q   Before installing, lubricate area which makes contact with plunger of slave cylinder with copper grease, e.g. Z 381 351 TE
11 - Release bearing
q   With or without plastic ring, depending on version → Fig.
q   Checking and servicing release bearing with glued plastic ring → Fig.
q   Checking release bearing with mechanically attached plastic ring → Fig.
q   Renew if groove worn on plastic ring is too deep → Fig.
q   Do not wash out bearing; wipe clean only
q   Renew bearing if noisy
q   Retainer lugs on release bearing must engage in release lever
12 - Clutch slave cylinder
q   Do not operate clutch pedal after slave cylinder has been removed
q   Disconnecting pipe/hose assembly → Fig.
q   Connecting pipe/hose assembly → Fig.
q   Removing and installing → Chapter
q   Follow correct procedure when bleeding → Chapter
q   Tighten bleeder valve to 4.5 Nm
13 - Hexagon socket head bolt
q   23 Nm
q   Clutch slave cylinder to gearbox
q   Self-locking
q   Always renew
14 - Bracket
q   For pipe/hose assembly
q   Attached to gearbox together with slave cylinder
15 - Plunger
q   Lubricate end of plunger with copper grease, e.g. Z 381 351 TE

   
Disconnecting slave cylinder from pipe/hose assembly
–  To remove pipe/hose assembly, use a screwdriver to lever off clip -A- as far as the stop. Only then can the pipe/hose assembly be pulled out.
  A30-0029
Connecting slave cylinder to pipe/hose assembly
–  Press in clip -A- onto stop.
–  Push pipe/hose assembly into clutch slave cylinder until it engages audibly.
–  Pull on pipe/hose assembly to check it is secure.
  A30-0103
Checking and servicing release bearing with glued plastic ring
l  Identification: inner side of plastic ring has three lugs -arrows-.
The plastic ring -arrows- may come loose from the release bearing when the gearbox or release bearing is removed. The release bearing does not have to be renewed if this happens.
–  Before installing the gearbox, glue the loose plastic ring back onto the release bearing with adhesive -AMV 195 KD1 01-.
l  The three square lugs -arrows- on the plastic ring engage in the recesses in the release bearing.
  Note
The release bearing must be renewed if the groove worn on the plastic ring is deeper than 0.8 mm.
  N30-0285
Checking release bearing with mechanically attached plastic ring
l  Identification: retaining tabs around plastic ring -arrows-.
  Note
t  The release bearing must be renewed if the plastic ring -1- has come loose.
t  The release bearing -3- must be renewed if the groove -arrow 2- worn on the plastic ring -1- is deeper than 0.8 mm.
  A30-10045

Removing and installing clutch slave cylinder > < Servicing clutch release mechanism