Audi Workshop Service and Repair Manuals

Exploded view - servicing clutch release mechanism

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Press tool -VW 412-

t	Press tool -VW 454-

t	Tube -2040-

t	Torque wrench -V.A.G 1331-

t	-1-Internal puller -Kukko 21/4-

t	-4-Counter-support -Kukko 22/1-

t	Locking fluid -AMV 185 101 A1-

t	Sealing grease -G 052 128 A1-

t	Copper grease (commercially available)

t	Adhesive -AMV 195 KD1 01-

t	Grease for clutch plate splines -G 000 100-

1 -	Release bearing

q	Do not wash out; wipe clean only

q	Renew bearing if noisy

q	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	Retainer lugs on release bearing must engage in release lever

2 -

TORX bolt

q

35 Nm

q

3x

q	Apply locking fluid -AMV 185 101 A1- when fitting

3 -	Clutch release lever

q	Before installing, lubricate area which makes contact with plunger of slave cylinder with copper grease (commercially available).

4 -	Retaining spring

q	Secure to clutch release lever

5 -	Guide sleeve

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

6 -

Oil seal

q	For input shaft

q	Pull out of guide sleeve → Item → Fig..

q	Press into guide sleeve → Item → Fig..

q	Pack space between sealing lip and dust lip half full with sealing grease -G 052 128 A1-

7 -

O-ring

q	Always renew

8 -	Dished spring

q	Inner diameter (convex side) faces guide sleeve → Item

9 -	Intermediate piece

q	Installation position: insert locating element between ribs of housing

10 -	Ball-head pin

q	Lubricate with grease for clutch plate splines -G 000 100-

11 -

Gearbox

12 -	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	Disconnecting pipe/hose assembly → Anchor

q	Follow correct procedure when bleeding → Chapter

q	Tighten bleeder valve to 4.5 Nm

13 -	Hexagon socket head bolt

q

23 Nm

q	Self-locking

q

Renew

14 -

Bracket

q	For pipe/hose assembly

q	Bolt to gearbox with clutch slave cylinder

15 -

Plunger

q	Lubricate end of plunger with copper grease (commercially available)

Checking and servicing release bearing with glued plastic ring 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-. The three square lugs -arrows- on the plastic ring engage in the recesses of the bearing ring. t  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 Identification: retaining tabs around plastic ring -arrows-. 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.

Pulling oil seal out of guide sleeve A -  Counter-support, e.g. -Kukko 22/1- B -  Internal puller 23.5 ... 30 mm, e.g. -Kukko 21/4-

Pressing oil seal into guide sleeve (press in onto stop)   Note The open side of the oil seal faces towards press tool -VW 454-. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-.