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Removing and installing slave cylinder > < Servicing clutch release mechanism

A4 Mk2

Clutch release mechanism - Exploded view
   
Clutch release mechanism - Exploded view
1 - Slave cylinder
q   Do not operate clutch pedal after slave cylinder has been removed.
q   Removing and installing → Chapter
q   When installing, press in slave cylinder so that securing bolt can be fitted easily
q   Grease lightly before installing → Anchor
q   Disconnecting pipe/hose assembly → Anchor
q   Follow correct procedure when bleeding → Chapter
q   Tighten bleeder valve to 4.5 Nm.
2 - Hexagon socket head bolt
q   23 Nm
q   Slave cylinder to gearbox
q   Self-locking
q   Always renew
3 - Bracket
q   For pipe/hose assembly
q   Attached to gearbox together with slave cylinder
q   Installing → Fig.
4 - Plunger
q   Lubricate end of plunger with copper grease -Z 381 351 TE-
5 - Dished spring
q   Smaller diameter (convex side) faces guide sleeve
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 - Torx socket head bolt
q   Self-locking
q   Renew
q   Black: only for aluminium gearboxes
q   Bright metal: for aluminium and magnesium gearboxes
q   For correct version, refer to → Electronic parts catalogue
q   Tighten to 35 Nm on aluminium gearboxes
q   Tighten to 25 Nm on magnesium gearboxes
8 - Release bearing
q   With or without plastic ring, depending on design
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
9 - Clutch release lever
q   Before installing, lubricate area which makes contact with plunger of slave cylinder with copper grease -Z 381 351 TE-.
10 - Retaining spring
q   Secure to clutch release lever
11 - 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.
q   Guide sleeve is made of different materials for aluminium and magnesium gearboxes
q   For correct version, refer to → Electronic parts catalogue
12 - O-ring
q   Renew
13 - Intermediate piece
14 - Ball head stud
q   Ball head stud is made of different materials for aluminium and magnesium gearboxes
q   Lubricate with MoS2 grease
q   Tighten to 25 Nm on aluminium gearboxes
q   Tighten to 18 Nm on magnesium gearboxes
q   For correct version, refer to → Electronic parts catalogue
15 - Gearbox

   
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 bearing with adhesive -AMV 195 KD1 01-.
l  The three square lugs -arrows- on the plastic ring engage in the recesses of the bearing ring.
  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 slave cylinder > < Servicing clutch release mechanism