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

Servicing clutch release mechanism Servicing clutch release mechanism 1.Gearbox 2.Ball stud
â—† Tighten to 25
Nm
â—† Lubricate with MoS2-grease 3.Intermediate piece 4.Dished washer
â—† Smaller
diameter
(convex side)
to guide
sleeve
5.O-ring
â—† Replacing
6.Replace input shaft sealing ring
â—† is available
as a
replacement
part together with the guide sleeve -Item
7-
â—† Pack space
between
sealing and
dust lips half-
full with
sealing grease G 052 128 A1.
7.Guide sleeve â—† Is available as
a replacement
part together
with the
sealing ring -
Item 6-
â—† Installation
position: The
oil drain bore
points
downwards.
â—† Before removing/fitting in order to
protect the
sealing ring -
Item 6- pull
shrink-fit hose
over the
splines on the
input shaft
8.Retaining spring Page 1 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

â—† Secure to clutch release lever
9.Torx socket head
bolt - 35 Nm
â—† Self-locking
â—† Replacing
10.Clutch release
lever
â—† Before
installing,
coat contact
surface of
clutch slave
cylinder push
rod with
copper grease, e.g. Z 381 351 TE. 11.Release bearing â—† With or
without
plastic ring, depending on version
=>Fig.1
â—† Cement
detached plastic ring => Fig.1
â—† Do not wash
out bearing,
only wipe
â—† Replace
noisy
bearings
â—† Engage
retaining
latches at the
release
bearing in
contact
release lever 12.Slave cylinder
â—† Do not Page 2 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

operate clutch
pedal after slave cylinder has been
removed.
â—† Removing => Fig.2
â—† Detach from
hose/pipe
assembly =>
Fig.3
â—† Installing =>
Fig.4 and
Fig.5
â—† When
installing, press in slave cylinder far
enough so
that securing
bolt can be
fitted easily.
â—† Follow
correct work
sequence
when
bleeding =>
Page 30-30
â—† Tighten bleed valve to 4.5
Nm 13.Hexagon socket-head bolt - 23Nm
â—† Slave
cylinder to
gearbox
â—† Self-locking
â—† Always
replace
14.Bracket
â—† For hose/pipe assembly
â—† Attached
together with
the slave cylinder to the gearbox
â—† Installing =>
Fig.5
15.Push rod
â—† Lubricate end of push rod
with copper grease, e.g. Z 381 351 TE Page 3 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

→ Fig.1 Repairing release bearing with plastic ring
In the case of release bearings with plastic
ring it is possible that the plastic ring
detaches from the release bearing during
removal of the gearbox. This does not signify
that replacement of the release bearing is
necessary.
‒ Cement the loose plastic ring to the
bearing ring with adhesive AMV 195 KD1
01 before installing the gearbox.
Three rectangular lugs -arrows- on the plastic
ring engage into recesses in the bearing ring.
Note:
If the plastic ring has become embedded deeper
than 0.5 mm in the bearing surface, the bearing
ring must be replaced. → Fig.2 Removing slave cylinder Page 4 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

‒ Unscrew the hexagon socket-head bolt -
arrow- and then pull the slave cylinder to
the rear out of the gearbox. → Fig.3 Detaching slave cylinder from hose/pipe assembly
Removing
‒ To remove the hose/pipe assembly, lever
out clip -A- to the stop using a screwdriver. Only then can the hose/pipe assembly be
pulled out.
Installing
‒ Press in clip -A- to stop.
‒ Push hose/pipe assembly into slave
cylinder until it engages audibly.
‒ To check, pull on the hose/pipe assembly. → Fig.4 Coat clutch slave cylinder with grease before installing
‒ Lightly lubricate contact surface for push
rod at clutch release lever with copper
grease, e.g. Z 381 351 TE.
‒ Before fitting slave cylinder into gearbox
housing, lubricate area -a- on boot with
lithium grease G 052 150 A2. → Fig.5 Installing clutch slave cylinder Notes:
â—† If the clutch slave cylinder -4- is inserted Page 5 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

off-line there is a danger that the push rod
will be guided past the clutch release
lever.
â—† When installing, press in the clutch slave
cylinder far enough so that the securing
bolt can be fitted easily.
â—† Renew securing bolt -2-.
â—† Carefully press the clutch pedal after the
slave cylinder has been installed. If an unusually hard pressure point is noticeable when the pedal is pressed, the clutch
pedal must not be pressed any further.
The tappet of the slave cylinder has
probably been moved past the clutch
release lever. The slave cylinder will be
destroyed with a pedal force of approx.
300 N and above.
‒ Engage bracket for hose/pipe assembly -3- at the slave cylinder -4- and bolt to
gearbox with slave cylinder.
‒ When inserting the clutch slave cylinder
into the mounting bore of the gearbox
housing, keep it aligned with the working
direction of the push rod. Page 6 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

Servicing clutch Servicing clutch Special tools and workshop equipment
required
â—† 3067 Counterhold
â—† 3176 Centring
mandrel
â—† V.A.G 1331 Torque
wrench
Notes:
â—† Observe the general
repair instructions
=>Page 00-17.
â—† If the clutch has burnt out, thoroughly clean
the bell housing,
flywheel and parts of
the engine facing the
gearbox in order to
prevent odours.
â—† Two different
versions of the dual-
mass flywheels may
be fitted. Distinguishing feature of the weight-
optimised dual-mass
flywheel => Fig.2.
â—† To prevent damage
to the weight-
optimised dual-mass
flywheel when
removing it, the
removal instructions
must be observed=>
Fig.2.
â—† Replace clutch plates and pressure plates
with damaged or
loose rivets.
â—† Pressure plates with
severely bent or
broken spring
connections must be
replaced => Fig.4
â—† Replace clutch plates and pressure plates
with damaged or
loose rivets.
â—† Select the correct
clutch plate and
pressure plate
according to engine
code:
=> Parts List
â—† Clean input shaft
splines and (in the
case of used clutch Page 1 of 75-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141315.xml?xsl=2

plates) the hub splines.
Remove corrosion
and apply only a very thin coating of grease G 000 100 to the
splines. Then move clutch plate to and for on input shaft until
hub moves freely on
shaft. Excess grease
must be removed.
â—† Pressure plates are
protected against
corrosion and
greased. Only the
contact surface may be cleaned, otherwise the service life of the
clutch will be
considerably
reduced.
â—† Tighten securing
bolts in small steps in
diagonal sequence to
avoid damaging
centring holes in
pressure plate and
centring pins on
flywheel.

‒ Remove the gearbox
to work on the
clutch=>Page 34-35.
1.Flywheel/dual mass
flywheel
â—† Ensure that
centring pins
are a tight fit.
â—† Contact
surface for
clutch lining must be free of grooves, oil
and grease
â—† Observe
removal
instructions for
the weight-
optimised dual-
mass flywheel
=>Fig.2
â—† Removing and
installing:
=> Relevant
engine
workshop
manual,
Mechanical
components;
Repair group
13 Page 2 of 75-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141315.xml?xsl=2

2.Bolt for flywheel â—† Always replace â—† Vehicles
without dual
mass flywheel
60 Nm + turn
90° further
â—† With dual-
mass flywheel ‒ Screw length
22.5 mm
60 Nm + turn
90° further
‒ Screw length
43 mm
60 Nm + turn
180° further
3.Detach clutch plate
â—† Installation
position:
‒ Spring pack
(coil springs)
towards thrust
and gearbox
‒ Clutch lining
must make full Page 3 of 75-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141315.xml?xsl=2

contact with
flywheel
‒ Marking "Getriebeseite" (if present) must
face towards
thrust plate and
gearbox
â—† Do not grease
â—† Clutch plate diameter => from Page 00-3
â—† Centring =>Fig.1 â—† Lightly grease
splines 4.Thrust plate â—† Removing and
installing
=>Fig.1
â—† Check ends of
diaphragm
spring=> Fig.3 â—† Checking
spring
connection
and riveted
fastenings =>
Fig.4
â—† Check wire
ring => Fig.5
5.Bolt - 25 Nm
â—† Loosen and
tighten
gradually in
several stages
working
diagonally
6.Needle bearing
â—† Check for
damage and
wear
â—† Removing and Page 4 of 75-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141315.xml?xsl=2