brake 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

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 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

Servicing clutch mechanism Removing and installing master cylinder Special tools and workshop equipment required
◆ Hose clamps 3094
Removing
Notes: ◆ Make sure that no brake fluid escapes into the plenum chamber or onto the gearbox 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.
‒ → Remove cover -1- above plenum
chamber where fitted. ‒ → Clamp off supply hose -A- leading to brake fluid reservoir using special
tool 3094. Detach hose at master
cylinder and plug it.
‒ Remove rubber grommet from cross
panel above connection pipe for
supply hose.
‒ Lever out retaining clip -C- with a
screwdriver and then pull out pipe -
B- slightly.
Old version with internal torx socket-
head bolts: Page 1 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2

‒ → Unscrew the two torx socket-head bolts -arrows-. New version with external torx socket-head bolts:
‒ → Unscrew bolt for brake fluid
reservoir -1- and detach fluid level
connector downwards.
Note:
The brake fluid reservoir is not removed. Notes: Page 2 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2

◆ For the sake of clarity, the brake fluid reservoir is not shown here.
◆ To remove the upper torx bolt, the
brake fluid reservoir must be
swivelled slightly to one side.
‒ → Remove the two torx bolts -
arrows-. All models: ‒ Remove driver's storage
compartment: => General Body Assembly, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage compartment
‒ → Detach clutch pedal from master
cylinder. For this purpose, unclip pin
using a screwdriver -arrow 1- and
pull out pin -arrow 2-.
Note: ◆ → During the following steps ensure
that the clutch pedal does not press
the clutch pedal switch -1- 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 switch may only be fitted once
to ensure that it is sufficiently tight.
‒ Unscrew retaining bolts for master
cylinder -arrow 2- and mounting
bracket -arrow 3-.
‒ Pull the complete pedal cluster
slightly towards the passenger compartment and take out the clutch master cylinder -4-. Installing Page 3 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2

Installation is carried out in the reverse
order; note the following:
‒ → Insert the master cylinder so that
seal -1- and the washer lie behind
the mounting bracket and tighten
bolts -2- to 20 Nm.
‒ Press connection pipe -3- with guide
-arrow A- into recess -arrow B- on
mounting bracket. A second mechanic is required for the next
step.
‒ → Slide the complete pedal cluster
forwards towards the cross panel,
insert the bolt -arrow 3- and tighten it finger tight. The second mechanic should guide the pipe into the master cylinder starting from the plenum
chamber. Old version with internal torx socket-head bolts:
‒ → Tighten the retaining bolts for the
brake servo -arrows- to 25 Nm.
New version with external torx socket-
head bolts: ‒ → Tighten the retaining bolts for the Page 4 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2