brake AUDI A4 1999 B5 / 1.G 01A Transmission Clutch Mechanism Service Workshop Manual

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.
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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

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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)
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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
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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.
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Clutch hydraulic system, servicing

1 -
Brake fluid reservoir
2 -
Supply hose
For clutch master cylinder
3 -
Hose/line assembly With threaded connections on clutch
master cylinder and clutch slave cylinder
4 -
Line fitting 15 Nm (11 ft lb)
5 -
Mounting bracket
6 -
Clutch pedal Removing and installing Page 30
-5
7 -
Socket-head bolt
20 Nm (15 ft lb)
8 -
9Pin and locking plate
10 -
Clutch master cylinder Removing and installing Page 30
-13
11 -
Transmission
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CAUTION!
Do not operate after the clutch pedal has been
removed.
Brake fluid must not be allowed to get onto the
transmission.
CAUTION!
Fill the brake fluid reservoir up to the "max"
marking with brake fluid before bleeding the
hydraulic clutch system with the brake bleeder. 12 -
Clutch slave cylinder

Coat plunger of clutch slave cylinder with
copper grease e.g. Z381 351 TE
For clutch slave cylinders with plastic support
ring, lightly lubricate outer surface of ring before
installing
When installing, push in until bolt can be
installed
13 -
Bleeder valve
4.5 Nm (40 in. lb)Observe all CAUTIONS, WARNINGS,
Notes and procedures when bleeding
Page 30
-17

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CAUTION! - Remove both nuts -A-
- Lift E-box out at rear of threaded bolt and remove from mounting point -
B-.
When carrying out the following steps, make sure that no brake
fluid escapes into the plenum chamber or onto the transmission
below. If this does occur, clean thoroughly. When working in the area of the footwell, make sure to protect the
carpeting from brake fluid which may run out.

- Clamp supply hose -A- from brake fluid reservoir using 3094 hose
clamp. Pull hose off clutch master cylinder and plug hose.
- Disconnect line -B- from clutch master cylinder and seal.
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- Connect clutch master cylinder to clutch pedal.
Secure pin and locking plate on clutch pedal.

To install E-box in plenum chamber: - Tighten line fitting -B- to clutch master cylinder to 15 Nm (11 ft lb).
- Slide hose -A- onto brake fluid reservoir up to stop.
- Bleed hydraulic clutch system after installing clutch master cylinder
Page 30
-17
.

- Always replace seal -C-.
- Make sure seal is positioned properly, and does not cover opening or
stepped metal edge.
- Install E-box by hand and evenly tighten nuts -A- to 4 Nm (35 in. lb)
(i.e. imprint on E-box cover).
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Clutch system, bleeding


Special tools and equipment

VAG1238B brake filling and bleeding appliance
or
VAG1869 brake filling and bleeding appliance

WARNING!

Brake fluid is poisonous.
It must NEVER be removed by siphoning
with your mouth.
If brake fluid contacts skin or eyes, flush or
wash adequately to prevent irritation. Get
medical attention immediately if necessary.
Brake fluid must be disposed of properly.
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