Audi Workshop Service and Repair Manuals

Exploded view - servicing clutch release mechanism

Special tools and workshop equipment required

t	Thrust plate -VW 402-

t	Press tool -VW 412-

t	Press tool -VW 454-

t	Torque wrench -V.A.G 1331-

t	-1-Internal puller -Kukko 21/5-

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

t	Sealing grease -G 052 128 A1-

t	Adhesive -AMV 195 KD1 01-

t	Copper grease (commercially available)

1 -	Clutch slave cylinder

q	Removing and installing → Chapter

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

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

q	Bleeding clutch system → Chapter

q	Tighten bleeder valve to 4.5 Nm

2 -	Hexagon socket head bolt

q

23 Nm

q	Clutch slave cylinder to gearbox

q	Self-locking

q	Always renew

3 -

Bracket

q	For pipe/hose assembly

q	Bolt to gearbox with clutch slave cylinder

4 -

Plunger

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

5 -

O-ring

q	Always renew → Fig.

q	Lubricate with gear oil before installing

6 -

Oil seal

q	For input shaft

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

q	Installation depth → 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 -	Guide sleeve

q	Removing and installing → Fig.

q	Before removing and installing, cover input shaft splines with a shrink-fit hose to protect oil seal

8 -	Clutch release lever

q	Removing and installing → Fig.

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

9 -	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

10 -

Bolt

q

24 Nm

q	Self-locking

q	Before installing bolt, clean thread with wire brush and then apply locking fluid -AMV 185 101 A1-

11 -	Leaf spring

12 -

Bolt

q

24 Nm

q	Self-locking

q	Before installing bolt, clean thread with wire brush and then apply locking fluid -AMV 185 101 A1-

13 -	Retaining piece

q	For guide sleeve

q	Removing and installing → Fig.

14 -	Intermediate piece

q	Renew if damaged

15 -

Gearbox

Removing and installing clutch release lever Removing –  Slacken off bolt -1- and remove leaf spring -2-. –  Remove clutch release lever -3- with release bearing. –  Disengage retaining tabs of release bearing at release lever. Installing –  Before installing clutch release lever, apply a thin coat of copper grease (commercially available) to contact surface for plunger of clutch slave cylinder. –  Fit clutch release lever -3- with release bearing onto guide sleeve. –  Insert leaf spring -2-. –  Clean thread of bolt -1- with a wire brush. Then insert bolt -1- with locking fluid -AMV 185 101 A1- and tighten to 24 Nm.

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.

Removing and installing guide sleeve Removing –  Unscrew bolts -arrows- and remove retaining piece -1-. –  Fit a thin insulating hose or shrink hose tightly over splines of input shaft. –  Pull guide sleeve -2- out of gearbox housing. Installing –  Renew O-ring in gearbox housing → Fig.. l  A thin insulating hose or shrink hose is fitted tightly onto input shaft splines. –  Pack space between sealing lip and dust lip half-full with sealing grease -G 052 128 A1-. –  Coat outer circumference of guide sleeve with gear oil. –  Push guide sleeve -2- over input shaft and into gearbox housing. –  Remove insulating hose/shrink hose. –  Fit retaining piece -1-. –  Clean threads of bolts -arrows- with a wire brush. Then insert bolts with locking fluid -AMV 185 101 A1- and tighten to 24 Nm.

Renew O-ring –  Pry out O-ring -arrow- using a small screwdriver. –  Lubricate new O-ring with gear oil before installing.

Pulling oil seal for input shaft out of guide sleeve A -  Counter-support, e.g. -Kukko 22/1- B -  Internal puller 30 ... 37 mm, e.g. -Kukko 21/5-

Installation depth - oil seal for input shaft Dimension x = 7.75 mm ± 0.5 mm

Pressing oil seal for input shaft into guide sleeve –  Lightly lubricate outer circumference of oil seal with gear oil. –  Press in oil seal for input shaft → Fig. „„Installation depth - oil seal for input shaft““. Make sure oil seal remains straight. l  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-.