AUDI A4 1999 B5 / 1.G 01W Transmission Clutch Mechanism Servicing Workshop Manual

30-1


Clutch mechanism, servicing

Notes:

Determine the correct coding for the anti-theft
radio (if equipped).
Switch the ignition off and disconnect battery
Ground (GND) strap.
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

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.
When working in the floor area, cover the
carpet with a cloth to protect against any
leaking brake fluid.
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30-2


Clutch pedal and clutch control overview

1 -
Mounting bracket
Removing and installing Repair Manual,
Brake System, Repair Group 46
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
-4
7 -
Pin and locking plate
Clip onto clutch pedal
8 -
Locking clip
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30-3


9 -
Clutch master cylinder
Removing and installing Page 30
-11
Do not operate after clutch pedal has been
removed
10 -
Socket-head bolt 20 Nm (15 ft lb)
11 -
Mount Insert in mounting bracket with over-center
spring
12 -
Over-center spring Application parts catalogRemove and install together with clutch
pedal Page 30
-4
13 -
Socket-head bolt
5 Nm (44 in. lb)Secures pivot pin for clutch and brake
pedal
14 -
Seal
15 -
Torx bolt 25 Nm (18 ft lb)Also secures brake master cylinder to
brake servo
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30-4

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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30-5

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.
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30-6


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

Note:
The Clutch Pedal Position Switch (CCP) -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 -
5Pin and locking plate
Latched in clutch pedal
6 -
Clutch pedal Removing and installing Page 30
-4
7 -
Clip
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30-7


8 -
Bracket for harness connector
9 -
Clutch Pedal Position (CPP) switch -F194-
Adjusting Page 30
-8
10 -
Clip
11 -
Screw and washer assembly
8 Nm (71 in. lb)
12 -
Mounting plate
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30-8

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 +/- 0.2 mm
(0.126 in. +/- 0.008 in.) between operating surface of clutch pedal and
switch cam.
- Move switch -B- toward gauge -A- until stop, and tighten two mounting
bolts (arrows) to 8 Nm (71 in. lb).
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30-9


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 nut 15 Nm (11 ft lb)
5 -
Mounting bracket
6 -
Clutch pedal Removing and installing Page 30
-4
7 -
Socket-head bolt
20 Nm (15 ft lb)
8 -
Pin and locking plate
9 -
Clutch master cylinder Removing and installing Page 30
-11
10 -
Transmission
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30-10


11 -
Clutch slave cylinder
Installing Page 30
-20
After working on hydraulic clutch
mechanism, bleed clutch slave cylinder
Page 30
-15

Do not press clutch pedal after clutch slave
cylinder has been removed
12 -
Bleeder valve 4.5 Nm (40 in. lb)Observe all CAUTIONS, WARNINGS,
Notes and procedures when bleeding
Page 30
-15

13 -
Bracket
Mounted to transmission
14 -
Bolt 25 Nm (18 ft lb)
15 -
Nut 2 Nm (18 in. lb)
16 -
Seal
17 -
Seal Must not be removed
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