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

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

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 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

12.Slave cylinder ◆ With plug
connection
pipe/hose
◆ Detach from
hose/pipe
assembly =>
Fig.1
◆ Brake fluid must not come into
contact with the
gearbox
◆ Removing and
installing
=>Page 30-34
◆ Do not operate
clutch pedal
after slave
cylinder has
been removed.
◆ Grease lightly
before installing=>Page 30-34.
◆ When installing, push on until the securing bolt Page 2 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141311.xml?xsl=2

can be fitted
◆ Follow correct work sequence when bleeding
=> Page 30-30 13.Bleed valve
◆ Tighten to 4.5
Nm
◆ Follow correct work sequence when bleeding
=> Page 30-30 ◆ A broken
bleeder valve
can be
screwed out
with a 3 mm
hexagon
socket wrench 14.Dust cap 15.Securing clip
◆ To remove the
line, pull out
the clamp =>
Fig.1
16.Bracket
◆ Secured to
gearbox
17.Hexagon socket-
head bolt - 23Nm
◆ Slave cylinder
to gearbox
◆ Self-locking
◆ Always replace 18.Nut - 2 Nm
19.Seal Page 3 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141311.xml?xsl=2

→ Fig.1 Removing clutch slave cylinder and detaching pipe
Removing
‒ To remove the pipe, lever out the clamp -A-
to the retainer using a screwdriver. Only
then can the pipe be removed.
Installing
‒ Press in securing clip -A- to stop.
‒ Push pipe into slave cylinder until it audibly
engages. Page 4 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141311.xml?xsl=2

brake servo -arrows- to 25 Nm. ‒ → Screw in the bolt for the brake
fluid reservoir -1- and attach the
connector for fluid level.
All models: ‒ → Tighten the hexagon socket head
bolt -arrow B- for securing pedal
cluster to dash panel crossmember
to 25 Nm. ‒ Connect clutch pedal to master Page 5 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2

◆ Secure to clutch release lever
9.Torx socket head
bolt - 35 Nm
◆ Self-locking
◆ Replacing
10.Clutch release
lever
◆ Before
installing,
coat contact
surface of
clutch slave
cylinder push
rod with
copper grease, e.g. Z 381 351 TE. 11.Release bearing ◆ With or
without
plastic ring, depending on version
=>Fig.1
◆ Cement
detached plastic ring => Fig.1
◆ Do not wash
out bearing,
only wipe
◆ Replace
noisy
bearings
◆ Engage
retaining
latches at the
release
bearing in
contact
release lever 12.Slave cylinder
◆ 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