brake AUDI A6 1996 C5 / 2.G 01E Transmission Clutch Mechanism Service Workshop Manual

30-1


Clutch mechanism, servicing

Note:

For vehicles with coded radio, obtain and note
the radio code.
Disconnect battery Ground strap with the
ignition switched off.
Lubricate all bearings and contact surfaces with
G 052 142 A 2 polycarbamide grease.
Before working on pedal cluster, remove cover
below dash panel:

Repair Manual, Body Interior, Repair Group
68


Make sure that no brake fluid escapes into the
footwell, the plenum chamber or onto the
transmission below. If this does happen, clean
the affected areas thoroughly.
When performing work in the footwell, put
cloths on the carpet to protect it from possible
brake fluid spills.
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30-2


Pedal cluster, assembly overview

Repair Manual, Brake System, Repair Group 46

1 -
Mounting bracket
Detach steering column from steering box
before removing
2 -
Pivot pin
For clutch pedal and brake pedalInstallation position: groove (arrow)
towards clutch pedal
3 -
Locking clip
4 -
Hex socket head bolt, 25 Nm
5 -
Brake pedal
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30-4


Parts catalog 12 -
Over-center spring
AllocationRemove and install with clutch pedal
Page 30
-5
13 -
Hex socket head bolt, 5 Nm
Secures clutch and brake pedal pivot pin
14 -
Seal Must not be removed
15 -
Torx bolt - 25 Nm Also secures the brake master cylinder
with brake servo
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30-6


- Unscrew bolt (arrow).
- Press clutch and brake pedal pivot pin out to the right, until the clutch
pedal can be removed.
- If necessary press brake pedal securing clip off pivot pin with a
screwdriver.
- Take out clutch pedal and over-center spring.
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30-7

Installing
Installation is carried out in the reverse order,
when doing this note the following:

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

Do not tighten bolt (arrow) until both securing clips have been fitted on the
clutch pedal/brake pedal pivot pin.
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30-12


Hydraulic system, general layout

Parts catalog 1 -
Brake fluid reservoir
2 -
Supply hose
3 -
Line/hose assembly
For plug-in connections on master cylinder
and slave cylinder Disconnecting from master cylinder and
installing Page 30
-18

Disconnecting from slave cylinder Fig. 2Allocation
4 -
Mounting bracket
5 -
Clutch pedal
Removing and installing Page 30
-5
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30-14


12 -
Plastic slave cylinder
Do not operate clutch pedal after slave
cylinder has been removed Brake fluid must not be allowed to get onto
the transmission Lightly grease to install Fig. 1When installing push in until the securing
bolt can be fitted. With plug-in connection for hose/line
assembly Disconnecting hose/line assembly Fig. 2Follow correct sequence of work when
bleeding Page 30
-25
.
13 -
Bleeder valve
Tighten to 4.5 NmFollow correct sequence of work when
bleeding Page 30
-25

A broken off bleeder valve can be removed
using a 3mm hex socket wrench
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30-18


Note: - Unscrew both nuts -A-.
- Lift E-box off studs at the rear and then pull it out of securing point -B-.
In the following procedures, 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 performing work in the footwell, put cloths on the carpet to
protect it from possible brake fluid spills.

- Clamp supply hose -A- from brake fluid reservoir using special tool
3094. Pull hose off master cylinder and plug hose.
- Remove rubber grommet for compensation hose above connecting line
from transverse wall.
- Pry out retaining clip -C- using a screwdriver and pull line -B- out
slightly.
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30-22


- Tighten bolts for brake booster (arrows) to 25 Nm.

- Press securing clip -C- in to stop.
- Insert tube -B- into master cylinder until the tube engages audibly.
- Insert rubber grommet -D- into transverse wall above connecting
tube/after-run hose -A-.
- Slide on after-run hose -A- to brake fluid reservoir to stop.
- Remove special tool 3094.
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30-25

Clutch system, bleeding


Special tools, testers and auxiliary items

Brake filling and bleeding appliance V.A.G 1238
B
or
Brake filling and bleeding appliance V.A.G
1869

Note:
First open bleeder valve before switching on
bleeding appliance.
When performing the following steps, make
sure that no brake fluid escapes onto the
transmission.
The clutch system must be bled after
performing work on hydraulic clutch
mechanism.
Top-up brake fluid reservoir to "max." marking
with brake fluid before bleeding clutch system.

- Pull clutch pedal back to its normal position.
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