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

30-20


Clutch release mechanism,
servicing
1 -
Transmission
2 -
Ball pivot pin
25 Nm (18 ft lb)Lubricate with MoS2 grease
3 -
Intermediate piece
4 -
Dished washer Smaller diameter (rounded side) faces
guide sleeve
5 -
O-ring Always replace
6 -
Seal for input shaft Pull out of guide sleeve using VW681
extractor lever Drive in onto stop using VW192 fitting
sleeve
7 -
Guide sleeve Before removing and installing, cover input
shaft splines with shrink-tube to protect
seal
8 -
Retaining spring
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Secure to clutch release lever
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9 -
Clutch release lever
Before installing, coat contact surface of
clutch slave cylinder plunger with thin layer
of copper grease, e.g. 381 351 TE
10 -
Torx bolt Always replace35 Nm (26 ft lb)Self-locking
11 -
Release bearing Do not wash-out bearing, wipe clean onlyReplace noisy bearings
12 -
Bolt

8DVA 000 504 socket-head bolt25 Nm (18 ft lb)

8DVA 000 505 socket-head bolt20 Nm (15 ft lb)
13 -
Clutch slave cylinder Tension clutch slave cylinder enough, so
that mounting bolts can be easily installed. Do not operate after clutch pedal has been
removed
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14 -
Plunger
Lubricate end of plunger with copper
grease, e.g. 381 351 TE
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30-22

Clutch, servicing


Special tools and equipment

3067 flywheel retainer
3176 centering mandrel

Notes:
Observe general repair instructions Page 00
-
14
.

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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30-23


CAUTION!
Clutch plates or pressure plates with loose or
damaged rivets must be replaced. - 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
B - Color marking on pressure plateWhite color marking -A- on dual-mass
flywheel must line up with white color
marking -B- on pressure plate
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30-24


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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30-25


CAUTION!
The pressure plate is treated against corrosion
and greased. Only the friction surface should be
cleaned, otherwise the service life of the clutch
will be considerably reduced. 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 Checking spring connection and rivets
Fig. 3

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30-26


5 -
Bolt
25 Nm (18 ft lb)Loosen and tighten in stages and in
diagonal sequence
6 -
Needle roller bearing
Removing and installingRepair Manual, Engine Mechanical, Repair
Group 13
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