AUDI A4 1996 B5 / 1.G 01A Transmission Clutch Mechanism Service Workshop Manual

30-1


Clutch mechanism, servicing

CAUTION!

Before disconnecting the battery:

Determine the correct coding for the anti-
theft radio.
Switch the ignition off (also applies when
connecting the battery). Failure to do so may
damage the Engine Control Module (ECM).
Part numbers are listed here for reference
only. Always check with your Parts
department for the latest information.

Notes:
Lubricate all bearings and contact surfaces with
G 052 142 A 2 polycarbamide grease.


Before
working on
the pedal
cluster,
remove the
driver's side
storage
compartment
Pa
ge 1 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

Repair Manual,
Body Interior, Repair Group 68


Make sure that no brake fluid escapes into the
plenum chamber or onto the transmission
below. If this does happen, clean the affected
areas thoroughly.
Pa
ge 2 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-2


Clutch pedal and clutch control overview

WARNING!

Clutch pedal travel must not be restricted by
extra carpets or floor mats.
Do not re-use fasteners that are worn or
deformed in normal use.
Some fasteners are designed to be used only
once, and are unreliable and may fail if used
a second time. This includes, but is not
limited to, nuts, bolts, washers, circlips and
cotter pins. Always follow recommendations
in this manual-replace these fasteners with
new parts where indicated, and any other
time it is deemed necessary by inspection.
1 -
Mounting bracket
Removing and installing Repair Manual, Brake System, Repair Group 46

Pa
ge 3 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-3


CAUTION!
Do not operate after the clutch pedal has been
removed. 2 -
Pivot pin
For clutch and brake pedalsInstallation position: groove (arrow) facing
clutch pedal
3 -
Locking clip
4 -
Socket-head bolt 25 Nm (18 ft lb)
5 -
Brake pedal
6 -
Clutch pedal Removing and installing Page 30
-5
7 -
8Pin and locking plate
Clip onto clutch pedal
9 -
Locking clip
10 -
Clutch master cylinder Removing and installing Page 30
-13
11 -
Socket-head bolt
20 Nm (15 ft lb)
Pa
ge 4 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-4


12 -
Mount
Insert in mounting bracket with over-center
spring
13 -
Over-center spring Application Parts catalog microficheRemove and install together with clutch
pedal Page 30
-5
14 -
Socket-head bolt
5 Nm (44 in. lb)Secures pivot pin for clutch and brake
pedal.
15 -
Seal
16 -
Torx bolt 25 Nm (18 ft lb)Also secures brake master cylinder to
brake servo
Pa
ge 5 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-5

Clutch pedal and over-center spring,
removing and installing


Removing

- Remove driver's side storage compartment Repair Manual, Body
Interior, Repair Group 68

- If installed, remove switch above clutch pedal.
- Unclip pin and locking plate using screwdriver (arrow -1-), remove pin
and locking plate (arrow -2-), and detach clutch pedal from clutch
master cylinder.
- Press locking clip for clutch pedal off pivot pin using screwdriver.

- Remove bolt (arrow).
- Press clutch and brake pedal pivot pin out toward right, until clutch
pedal can be removed.
- If necessary, press locking clip for brake pedal off pivot pin using
screwdriver.
- Remove clutch pedal and over-center spring.
Pa
ge 6 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-6

Installing
Installation is the reverse of removal, note the
following:

- Align pivot pin so that it protrudes out of mounting bracket on clutch
pedal side (arrow).
- Hook clutch pedal into over-center spring, then install onto pivot pin.
- Connect clutch pedal to master cylinder. Clip locking pin onto clutch
pedal.

- Do not tighten bolt (arrow) until both securing clips have been installed
on pivot pin.
Pa
ge 7 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-7


Clutch Pedal Position (CPP) switch -F194-,
removing and installing

Note:
The clutch pedal position switch -F194- allows the
engine to be started only with the clutch pedal
depressed. Introduction 05.97
1 -
Mounting bracket
Before removing, remove steering column
from steering gear Repair Manual, Suspension, Wheels, Steering, Repair Group 48

2 -
Cable bracket
3 -
Locking clip
4 -
Pin and locking plate
Latched in clutch pedal
5 -
Clutch pedal Removing and installing Page 30
-5
6 -
Clip
Pa
ge 8 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-8


7 -
Bracket for harness connector
8 -
Clutch Pedal Position (CPP) switch -F194-
Adjusting Page 30
-9
9 -
Clip
10 -
Screw and washer assembly
8 Nm (71 in. lb)
11 -
Mounting plate
Pa
ge 9 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1

30-9

Clutch Pedal Position (CPP) switch -
F194-, adjusting


- Loosen two bolts slightly (arrows).
- Have second technician fully depress clutch pedal up to stop.
- Place feeler gauge -A- with specific dimension -a- 3.2 mm (0.126 in.)
between operating surface of clutch pedal and switch cam.
Thickness -a- of feeler gauge: 3.2 mm (0.126 in.)
- Move switch -B- toward gauge -A- until stop, and tighten two mounting
bolts (arrows) to 8 Nm (71 in. lb).
Pa
ge 10 of 22 Clutch mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM02.30.1