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Audi Workshop Service and Repair Manuals

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Removing and installing clutch release lever, release bearing and guide sleeve > < Renewing needle bearing for dual-mass flywheel ("Sachs" and "LuK" versions)

A4 Mk3

Exploded view - clutch release mechanism
   
Exploded view - clutch release mechanism
1 - Ball-head pin
q   25 Nm
q   Coat bearing surface for clutch release lever -arrow A- with grease -G 000 100-
2 - Intermediate piece
q   Renew if damaged
3 - Retaining spring
q   Engage on clutch release lever
4 - Release bearing
q   Different versions
q   For correct version, refer to → Electronic parts catalogue
q   Do not wash out; wipe clean only
q   Renew bearing if noisy
  Note
t  Grease bearing surface for clutch release lever thoroughly with lubricating paste -G 000 150- → Fig..
t  Remove any existing grease in bearing surface for guide sleeve -arrow B-: the surface where the release bearing moves on the guide sleeve must be free of grease
q   Retainer lugs on release bearing must engage in release lever
q   Removing and installing → Chapter
Release bearing up to 02.2008
l  Inner diameter -arrow B-: 34 mm
l  Checking release bearing → Fig.
Clutch release bearing with tumbler ring - from 02.2008 onwards
l  Inner diameter -arrow B-: 36 mm
l  Checking release bearing with tumbler ring → Fig.
5 - Clutch release lever
q   Different versions
q   For correct version, refer to → Electronic parts catalogue
q   Remove existing grease from release lever
q   Re-grease bearing surface for release bearing -arrows C- with lubricating paste -G 000 150-
q   Removing and installing → Chapter
6 - Bolt
q   8 Nm
q   Different bolt length
q   For correct version, refer to → Electronic parts catalogue
q   2x
q   Apply locking fluid -AMV 185 101 A1- when fitting
7 - Retaining piece
q   For guide sleeve
  Note
t  Discontinued as of 02.2008
t  Is also omitted when new guide sleeve is installed → Item
t  For correct version, refer to → Electronic parts catalogue
8 - Guide sleeve
q   Different versions
q   For correct version, refer to → Electronic parts catalogue
q   Remove grease from guide sleeve -arrow D- – clutch release bearing must be fitted free of grease on guide sleeve
Guide sleeve up to 02.2008
l  Diameter -arrow D-: 34 mm
l  If renewed, install without retaining piece → Item
Guide sleeve from 02.2008 onwards
l  Fitted on clutch release bearing with tumbler ring → Fig.
l  Diameter -arrow D-: 36 mm
l  Is installed without retaining piece → Item
9 - Clutch slave cylinder
q   Removing and installing → 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr.30
q   Do not operate clutch pedal after slave cylinder has been removed
q   Observe correct sequence when bleeding → 6-speed manual gearbox 0B1, front-wheel drive; Rep. gr.30
q   When installing, push in until the securing bolt can be fitted.
10 - Gearbox

   
Checking release bearing (up to 02.2008)
l  The release bearing must be renewed if the plastic ring -1- has come loose.
l  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
Checking clutch release bearing with tumbler ring -1- - from 02.2008 onwards
Different versions:
t  Tumbler ring -1- with annular groove -arrow A-
t  Tumbler ring -1- without groove (when new)
t  Tumbler ring -1- with indentations -B- (used release bearing)
Check:
l  Axial and radial clearance is permissible on the tumbler ring -1- of the release bearing.
l  The tumbler ring (swash plate) -1- should be able to tilt to all sides in the release bearing -2-.
l  The tumbler ring is a relatively loose fit when the release bearing is not in contact with the clutch.
l  The release bearing must be renewed if the groove -arrow A- or the indentations -B- are deeper than 0.8 mm.
  A30-10224
Greasing release bearing
  Caution
Grating/creaking noises can occur when clutch is operated.
l  Lack of grease at the bearings -arrows- on the release bearing assembly can cause creaking/grating noises when the clutch is operated.
l  Grease bearings -arrows- on release bearing assembly thoroughly with lubricating paste -G 000 150-. A thin coating of grease is not sufficient.
l  Remove grease in bearing surface for guide sleeve: bearing of release bearing on guide sleeve must be free of grease.
  A30-10221

Removing and installing clutch release lever, release bearing and guide sleeve > < Renewing needle bearing for dual-mass flywheel ("Sachs" and "LuK" versions)