AUDI A6 2000 C5 / 2.G Changing Clutch 5Speed Manual Gearbox

Servicing clutch mechanism Assembly overview - Pedal cluster (LHD vehicles) 1.Bracket ◆ Detach
steering
column from
steering box
before
removing
=> Running Gear, FWD and 4WD; Repair group 48; Removing and installing steering column
2.Pivot pin
◆ For clutch
pedal and
brake pedal
◆ Installation
position:
groove (arrow)
towards clutch
pedal
3.Retainer
4.Hexagon socket
head bolt - 25 Nm
5.Brake pedal
6.Clutch pedal ◆ Removing and installing=>Page 30-5
7.Pin
◆ Clip onto clutch
pedal
8.Retainer
9.Master cylinder
◆ Removing and installing=>Page 30-22
10.Hexagon socket-head bolt - 20Nm
11.Mounting
◆ Insert in
mounting
bracket with
over-centre
spring Page 1 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141305.xml?xsl=2

12.Over-centre spring ◆ Allocation
=> Parts List
◆ Removing and
installing with
clutch pedal
=> Page 30-5
13.Hexagon socket-
head bolt - 5Nm
◆ 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 Page 2 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141305.xml?xsl=2

Page 3 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141305.xml?xsl=2

Servicing clutch mechanism Removing and installing clutch pedal with over-centre spring Removing ‒ Remove driver's side storage
compartment.
Note:
◆ → During the following steps ensure
that the clutch pedal does not press
the clutch pedal switch -F 36 -arrow- out of the retaining clip, as this would damage the thread of the switch, as
a result of which the switch would
have to be replaced.
◆ The clutch pedal switch -arrow- may
only be installed once in order to
ensure that it is sufficiently tight. ‒ → Detach clutch pedal from master
cylinder. For this purpose, unclip pin
using a screwdriver -arrow 1- and
pull out pin -arrow 2-.
‒ Press clutch pedal securing clip off
pivot pin with a screwdriver. ‒ → 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-
centre spring. Page 1 of 25-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141306.xml?xsl=2

Installing Installation is carried out in the reverse
order; note the following:
‒ → Align the clutch pedal/brake pedal pivot pin so that it protrudes out of
the mounting bracket at the clutch
pedal side (arrow).
‒ First hook the clutch pedal into the
over-centre 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.
‒ If fitted, check the adjustment of the
clutch pedal switch -F 36 => Page
30-11. Page 2 of 25-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141306.xml?xsl=2

Servicing clutch mechanism Adjusting clutch pedal switch -F 36 ‒ → Check the adjustment of the
clutch pedal switch -1- above the
clutch pedal as follows:
‒ The entire clutch pedal switch
-1- should lie against the
clutch pedal -3- and be fully
actuated.
‒ Adjustment tolerance Gap -a-
between retaining clip and
mounting bracket -2- and gap
-b- on switch -1- must not
exceed 0.7 mm.
‒ Hold the clip and turn clutch
pedal switch -1- to adjust the
setting.
Note:
Switch must only be installed once in order
to ensure that it is sufficiently tight. Page 1 of 15-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141307.xml?xsl=2

Servicing clutch mechanism Removing and installing clutch pedal switch -F 194 ◆ USA vehicles only
Note:
The clutch pedal switch -F
194 permits the engine to be
started only when the clutch pedal is pressed.
1.Bracket
2.Cable retainer
3.Retainer
4.Pin
◆ Clip onto clutch
pedal
5.Clutch pedal
◆ Removing and installing=>Page 30-5
6.Clip 7.Connector bracket
8.Clutch pedal switch
-F 194
◆ Adjusting =>
Page 30-11
9.Clamp
10.Combi bolts - 8 Nm
11.Mounting plate Page 1 of 25-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141308.xml?xsl=2

Page 2 of 25-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141308.xml?xsl=2

Servicing clutch mechanism Adjusting clutch pedal switch -F 194 ◆ USA vehicles only
‒ → Slightly loosen the two bolts -
arrows-.
‒ Have the second mechanic press the clutch pedal to the limit stop.
‒ Insert a feeler gauge -A-, set at
dimension -a- 3.2 ± 0.2 mm,
between contact surface of the
clutch pedal and switch plunger.
‒ Swivel switch -B- to stop towards
feeler gauge -A- and tighten the two
securing bolts -arrows- to 8 Nm. Page 1 of 15-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141309.xml?xsl=2

Servicing clutch mechanism Exploded view - Hydraulic system 1.Brake fluid reservoir 2.Supply hose
3.Hose/pipe assembly
◆ For plug
connections on
master/slave
cylinders
◆ Detaching from
slave cylinder
=> Fig.1
◆ Detaching from
master cylinder and installing => Page 30-22
◆ Allocation for
LHD and RHD
vehicles
=> Parts List
4.Bracket
5.Clutch pedal
◆ Removing and installing=>Page 30-5.
6.Hexagon socket-head bolt - 20 Nm
7.Pin
8.Master cylinder
◆ With plug
connection
pipe/hose
◆ Removing and installing=>Page 30-22
9.Seal
◆ Must not be
removed
10.Securing clip
◆ To remove the
line, pull out the
clamp => Page
30-22
11.Gearbox Page 1 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141311.xml?xsl=2