AUDI A4 1998 B5 / 1.G 01W Transmission Clutch Release Workshop Manual

30-17


Clutch release mechanism,
servicing
1 -
Clutch slave cylinder
Do not press clutch pedal after clutch slave
cylinder has been removed Installing Fig. 1Tension clutch slave cylinder enough so
that mounting bolts can be easily installed
2 -
Bolt
Hex bolt:Before installing, coat with D 185 400 A2
locking fluid Tightening torque: 25 Nm (18 ft lb)
Socket-head bolt:Always replaceSelf-lockingTightening torque: 20 Nm (15 ft lb)
3 -
Bracket for hose/line assembly Attach to clutch slave cylinderNot always present
4 -
Plunger
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Lubricate end of plunger with copper
grease, e.g. 381 351 TE
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5 -
Spring washer
Small diameter facing guide sleeve
(convex side)
6 -
Input shaft seal Use VW681 extractor lever to remove from
guide sleeve Use VW192 arbor to drive in to stop
7 -
Torx bolt Always replace35 Nm (26 ft lb)Self-locking
8 -
Throwout bearing Do not rinse out bearing, wipe clean onlyReplace noisy bearings
9 -
Clutch release lever Before installing, coat contact surface of
clutch slave cylinder plunger with layer of
copper grease, e.g. Z 381 351 TE
10 -
Retaining spring Secure to clutch release lever
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11 -
Guide sleeve
Before removing and installing, cover input
shaft splines with shrink-tube to protect
seal
12 -
O-ring Always replace
13 -
Intermediate piece
14 -
Ball pivot pin 25 Nm (18 ft lb)Lubricate with MoS2 grease
15 -
Transmission
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Fig. 1 Installing clutch slave cylinder
- Before installing, coat contact surface of clutch release lever plunger
with thin layer of copper grease, e.g. Z 381 351 TE.
- Before installing clutch slave cylinder in transmission, coat boot area -
a- with G 052 150 A2 lithium grease.
- Guide clutch slave cylinder into bore of transmission housing without
large sideways deviation from direction of motion of plunger.

Notes: - Attach bracket -3- for pressure line -1-.
If clutch slave cylinder -4- is inserted crooked, there is a possibility that
the plunger will be inserted past the clutch release lever. Pre-load the clutch slave cylinder enough so that the mounting bolt
can be easily installed.
- Install mounting bolt -2-.
- Install hex bolt with D 185 400 A2 locking fluid and tighten to 25 Nm
(18 ft lb).
If socket-head bolt is used, it is self-locking: always replace and tighten
to 20 Nm (15 ft lb).
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30-21

Clutch, servicing


Special tools and equipment

3067 flywheel retainer
3176 centering mandrel

Notes:
Observe general repair instructions Page 00
-
10
.

Replace clutch plates and pressure plates
which have damaged or loose rivets.
Select the correct clutch plate and pressure
plate according to the engine code parts
catalog.

Clean input shaft splines and (in the case of
used clutch plates) the hub splines. Remove
corrosion and apply only a very thin coating of
lubricant G 000 100 to the splines. Then move
clutch plate back and forth on input shaft until
hub moves freely on shaft. Excess grease must
be removed.

Pressure plates have an anti-corrosion coating
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and are greased. Only the contact surface may
be cleaned, otherwise the service life of the
clutch will be considerably reduced.
If the clutch has been burned out, thoroughly
clean the bellhousing, flywheel and parts of the
engine facing the transmission to reduce the
smell of burnt clutch.
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- Remove transmission to work on clutch Page
34
-18
.
A - Color marking on dual-mass flywheel
White color marking -A- on dual-mass
flywheel must line up with white color
marking -B- on pressure plate (if present)
B - Color marking on pressure plateWhite color marking -A- on dual-mass
flywheel must line up with white color
marking -B- on pressure plate (if present)
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30-23


Repair Manual, Engine Mechanical, Repair
Group 13 1 -
Dual-mass flywheel
Make sure centering pins are in place and
seated correctly Contact surface for clutch lining must be
free of dirt, oil and grease Removing and installing:
2 -
Bolt
Always replaceWith dual-mass flywheel: 60 Nm (44 ft lb) +
1/2 turn (180 ) Without dual-mass flywheel: 60 Nm (44 ft
lb) + 1/4-turn (90 )
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30-24


3 -
Clutch plate
Installation position: Spring pack (coil
springs) facing pressure plate. Clutch lining
must make full contact with flywheel.
Marking "Getriebeseite" (if provided) faces
pressure plate Do not lubricateClutch plate diameter Page 00
-3
Centering Fig. 1Lightly lubricate splines
4 -
Pressure plate Removing and installing Fig. 1Checking ends of diaphragm spring Fig. 2 Checking spring connection and rivets
Fig. 3

5 -
Bolt
25 Nm (18 ft lb)Loosen and tighten in stages and in
diagonal sequence
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