Audi Workshop Service and Repair Manuals

• Gearbox
• Ball stud
• ◆ Tighten to 25 Nm
• ◆ Lubricate with MoS2-grease
• Intermediate piece
• Dished washer
• ◆ Smaller diameter (convex side) to guide sleeve
• O-ring
• ◆ Replace
• Input shaft oil seal
• ◆ Pull out of guide sleeve with special tool VW 681
• ◆ Drive home using fitting sleeve VW 192

• Locating sleeve
• ◆ Before removing and installing, cover input shaft splines with a shrink-fit hose to protect oil seal.
• Retention spring
• ◆ Secure to clutch release lever
• Clutch release lever
• ◆ Before installing, coat contact surface of clutch slave cylinder push rod with copper grease, e.g. Z 381 351 TE.
• Torx socket head bolt
  - 35 Nm
• ◆ Self-locking
• ◆ Replace

• Release bearing
• ◆ Do not wash out bearing, only wipe
• ◆ Replace noisy bearings
• ◆ Engage retaining latches at the release bearing in contact release lever
• Bolt
• ◆ Fit hexagon bolt with locking compound D 185 400 A2.
• ◆ Up to ident. no. 8DVA 000 504
  Hexagon bolt - 25 Nm
• ◆ As of ident. no. 8DVA 000 505
  Hexagon socket-head bolt
  - 20 Nm
• Slave cylinder
• ◆ Do not operate clutch pedal after slave cylinder has been removed.
• ◆ Installing => Fig.1
• ◆ When installing, press in slave cylinder far enough so that securing bolt can be fitted easily.
• Push rod
• ◆ Lubricate end of push rod with copper grease, e.g. Z 381 351 TE

→ Fig.1    Installing clutch slave cylinder

• ‒ Lightly lubricate contact surface for push rod at clutch release lever with copper grease, e.g. Z 381 351 TE.
• ‒ Before fitting slave cylinder into gearbox housing, lubricate area -a- on boot with lithium grease G 052 150 A2.

• ‒ → Engage bracket for pressure pipe -3- at the slave cylinder -4- and screw together with slave cylinder at gearbox.
• ‒ When inserting the clutch slave cylinder into the mounting hole of the gearbox housing, keep it as far as possible in line with the direction of operation of the push rod.

Notes:

• ◆ If the clutch slave cylinder -4- is inserted off-line there is a danger that the push rod will be guided past the clutch release lever.
• ◆ When installing, press in the clutch slave cylinder far enough so that the securing bolt can be fitted easily.
• ◆ Renew securing bolt -2-.