brake 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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30-9


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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30-12


Notes: - 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 floor area cover the carpet with a cloth to protect
against any leaking brake fluid.

- 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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30-14

- 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
-15
.

- Always replace seal -C-.
- Make sure seal is positioned properly, and does not cover opening or
stepped metal edge.
- Install E-box into mounting point -B-.
- Tighten nuts -A- to 4 Nm (35 in. lb).
- Install cap and hand tighten in diagonal sequence to 4 Nm (35 in. lb)
imprint on E-box cover.
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30-15

Clutch system, bleeding


Special tools and equipment

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

Notes:
When carrying out the following steps, make
sure that no brake fluid escapes onto the
transmission.
The clutch system must be bled after carrying
out work on the hydraulic clutch mechanism.
Top off brake fluid reservoir to "MAX." mark
with brake fluid before bleeding clutch system.

- Pull clutch pedal back to rest position.

- Connect VAG1238B brake filling and bleeding
appliance or VAG1869 but do not switch on.
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30-16


Note:
While bleeding, make sure bleeder hose remains correctly routed. - Connect bleeder hose -A- to clutch slave cylinder (arrow) and open
bleeder valve.
- Connect bleeder hose with pressure hose to collector bottle.
- Switch on bleeding appliance and let approx. 100 cm3 (approx. 3.4 fl.
oz) brake fluid flow into suitable collection reservoir.
Work pressure: 2.5 bar (36 psi)
- Close bleeder valve.
Tightening torque: 4.5 Nm (40 in. lb).
- Depress clutch pedal several times after completion of bleeding
process.
- Bleed system again if necessary.
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