Audi Workshop Service and Repair Manuals

Servicing clutch release mechanism

1 -

Gearbox

2 -	Intermediate piece

q	Renew if damaged

3 -

Oil seal

q	For input shaft

q	Removing → Fig.

q	Installing → Fig.

q	Installation depth (factory): 3.5 mm, installation depth (repairs): 4.5 mm

4 -	Guide sleeve

5 -	Bolt, 15 Nm

q

3x

6 -	Clutch release lever

q	Different versions → Electronic parts catalogue

q	Removing → Fig.

q	Must engage in the lugs in intermediate piece when installed → Fig.

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

7 -	Leaf spring

8 -	Bolt, 25 Nm

q	Self-locking

q

Renew

9 -	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	Renew bearing if noisy

q	Retainer lugs on release bearing must engage in release lever

10 -	Clutch slave cylinder

q	Removing and installing → Chapter

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

q	Grease lightly before installing → Anchor

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

q	With plug-in connection for hose/pipe assembly

q	Disconnecting pipe/hose assembly → Anchor

q	Follow correct procedure when bleeding → Chapter

q	Tighten bleeder valve to 4.5 Nm.

11 -	Hexagon socket head bolt, 23 Nm

q	Slave cylinder to gearbox

q	Self-locking

q

Renew

12 -

Bracket

q	For pipe/hose assembly

q	Attached to gearbox together with slave cylinder

q	Installing → Anchor

q	Bolt onto gearbox with slave cylinder

13 -

Plunger

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

Removing input shaft oil seal –  Pry out oil seal carefully using a screwdriver -arrow-.   Note Take care not to damage contact surface for oil seal on input shaft.

Installing input shaft oil seal –  Lightly lubricate outer circumference of oil seal. –  Fill space between sealing lip and dust lip of new seal for input shaft with a thin coat of grease -G 052 128 A1-. –  Fit a thin insulating hose tightly over splines of input shaft. –  Drive in input shaft oil seal. l  Installation depth when fitted at factory: 3.5 mm. l  Installation depth when re-installing a used input shaft (repairs): 4.5 mm. –  Remove insulating hose.

Removing clutch release lever –  Slacken bolt -1-, remove leaf spring-2- and press back catch -arrow-. –  Remove clutch release lever -4- together with release bearing -3-. –  Disengage retaining tabs of release bearing at release lever.

Installing clutch release lever –  Before installing clutch release lever, apply a thin coat of copper grease -Z 381 351 TE- to contact surface for plunger of clutch slave cylinder. –  Insert clutch release lever -A- into intermediate piece -C- and engage (detent -B- will become visible). –  Fit leaf spring → Item and tighten the bolt → Item to 25 Nm.

Checking and servicing release bearing with glued plastic ring l  Identification: inner side of plastic ring has three lugs -arrows-.   Note The plastic ring 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  Three square lugs -arrows- of 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.

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.