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

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

Servicing clutch Servicing clutch Special tools and workshop equipment
required
◆ 3067 Counterhold
◆ 3176 Centring
mandrel
◆ V.A.G 1331 Torque
wrench
Notes:
◆ Observe the general
repair instructions
=>Page 00-17.
◆ 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.
◆ Two different
versions of the dual-
mass flywheels may
be fitted. Distinguishing feature of the weight-
optimised dual-mass
flywheel => Fig.2.
◆ To prevent damage
to the weight-
optimised dual-mass
flywheel when
removing it, the
removal instructions
must be observed=>
Fig.2.
◆ Replace clutch plates and pressure plates
with damaged or
loose rivets.
◆ Pressure plates with
severely bent or
broken spring
connections must be
replaced => Fig.4
◆ Replace clutch plates and pressure plates
with damaged or
loose rivets.
◆ Select the correct
clutch plate and
pressure plate
according to engine
code:
=> Parts List
◆ 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.
◆ 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.
◆ 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
◆ Ensure that
centring pins
are a tight fit.
◆ Contact
surface for
clutch lining must be free of grooves, oil
and grease
◆ Observe
removal
instructions for
the weight-
optimised dual-
mass flywheel
=>Fig.2
◆ 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

installing:
=> Relevant
engine
workshop
manual,
Mechanical
components;
Repair group
13 → Fig.1 Centring clutch plate and removing and installing thrust plate
‒ Loosen and tighten bolts gradually in
several stages working diagonally.
Tightening torque: 25 Nm.
‒ Reverse position of retainer 3067 when
removing.
‒ Installation position of clutch plate: spring
pack (coil springs) or marking
"Getriebeseite" towards pressure plate and
gearbox.
‒ Clutch lining and contact surface of
pressure plate must make full contact with
flywheel before securing bolts are inserted. ‒ Use mandrel 3176 to centre clutch plate.
→ Fig.2 Weight-optimised dual-mass flywheel
Identification: Cheese-head bolts -B- are
countersunk in the flywheel -A-. Page 5 of 75-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141315.xml?xsl=2

Removing Note:
In order to avoid destroying the weight-optimised
dual-mass flywheel during removal, the bolts -B-
must not be removed using a pneumatic or impact
driver. Only manual removal of the bolts -B- is permissible.
‒ Turn flywheel -A- until the bolts -B- are
positioned centrally with respect to the
holes -arrows-.
‒ When unscrewing bolts -B-, ensure that no
bolt heads are in contact with the flywheel -
arrows- to prevent damage as it turns. → Fig.3 Checking ends of the diaphragm spring
◆ Wear up to half the thickness of the
diaphragm spring is permitted.
Note:
When performing repairs always match up clutch pressure plate and clutch plate by checking engine code (see Parts Catalogue).
→ Fig.4 Checking spring connection and riveted fastenings
‒ Check the spring connections -arrows A- for damage and ensure the riveted fastenings -
arrows B- fit tightly.
Note:
Pressure plates with severely bent or broken
spring connections as well as loose riveted
fastenings must be replaced.
→ Fig.5 Checking wire ring ‒ Check the wire ring in the pressure plate -
arrow- for damage. Replace pressure plate
with broken wire ring. Page 6 of 75-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141315.xml?xsl=2

=> Engine, Mechanical Components; Repair group 26
‒ Removing propshaft => Page 39-81. ‒ → Detach selector rod -arrow A-.
‒ Unscrew hexagon socket head bolt
on push rod -arrow B-.
Note:
Shown in illustration with manual gearbox.
‒ Remove the front heat shield on the
left over the exhaust system.
‒ Swivel gear stick housing down
together with selector rod and push
rod and remove.
Installing
Installation is in reverse order.
‒ Push selector rod on so that the
securing bolt fits in the recess in the
selector shaft. ‒ → Then secure selector rod (arrow -
A-).
‒ Then bolt push rod to gearbox (arrow -B-).
‒ Adjusting gear selector mechanism
=> Page 34-11
‒ Install propshaft => Page 39-89.
‒ Tension free alignment of exhaust
system
=> Engine, Mechanical Components; Repair group 26
Tightening torques Page 2 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141317.xml?xsl=2

Removing gearbox Installing
Installation is carried out in the reverse order; note the following:
‒ Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Do not grease guide sleeve. It should be possible to push the clutch
plate back and forth slightly.
‒ Check clutch release bearing for
wear, replace if necessary.
‒ → If the plastic ring of the release
bearing is loose, it must be bonded
back onto the bearing ring with
adhesive AMV 195 KD1 01.
Three rectangular lugs -arrows- on the plastic ring engage into recesses in the bearing ring.
If any score marks deeper than 0.5 are present, the bearing ring must be replaced.
‒ Lightly lubricate contact surface for
push rod at clutch release lever with
copper grease, e.g. Z 381 351 TE.
‒ All threaded holes in which self-locking bolts are to be screwed must be cleaned of residual locking
compound using a thread tap.
‒ Check whether the dowel sleeves for centralising engine/gearbox are in
the cylinder block; install if
necessary. ‒ Renew all self locking nuts.
‒ If fitted, ensure that the intermediate
plate is correctly positioned on the
engine.
‒ → Lift gearbox until clutch slave
cylinder with bracket for hose/pipe
can be installed (arrow).
Note:
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. Page 1 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141329.xml?xsl=2

‒ Install lower engine/gearbox securing bolts and bolts for starter. For this
purpose, insert the starter.
=> Electrical System; Repair group 27; Removing and installing starter
‒ Bolt drive shafts to flange shafts.
=> Running Gear, FWD and 4WD; Repair group 40
‒ The threaded bores in the flange
shaft of the manual gearbox for the
propshaft must be cleaned of
remaining locking fluid with a thread
tap before assembling
‒ Replace front gaskets at propshaft
=> Page 39-79 and at drive shafts.
‒ Attaching propshaft => Page 39-84.
‒ Check selector rod and push rod,
adjust if necessary => Page 34-11.
‒ Tension free alignment of exhaust
system
=> 4-cylinder Engine (5-valve turbo), Mechanical Components; Repair group 26; Removing and installing parts of exhaust system; Stress-free alignment of exhaust system
=> 6-cylinder Engine (5-valve), Mechanical Components; Repair group 26; Removing and installing parts of exhaust system; Stress-free alignment of exhaust system
‒ Check oil level in manual gearbox => Page 34-56.
‒ Electrical connections and routing:
=> Current Flow Diagrams, Electrical Fault-
finding and Fitting Locations binder
‒ Connect the battery.
Notes:
◆ If the battery is reconnected, please
ensure that the vehicle equipment
(radio, radio/navigation system,
clock, electric window lifters) is
activated as described in the
operating instructions.
◆ Deactivate the service mode of the
telematics control unit.
=> Radio, Telephone and Navigation Page 2 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141329.xml?xsl=2

System; Repair group 91 Tightening torques → Gearbox to engine (4-cylinder)
A: Centring sleeves Item Bolt Nm
1, 3, 4 M12 x 67 65
2, 6 M12 x 90 65
5, 11 M12 x 110 65
7...10 M10 x 45 45 → Gearbox/engine assembly mountings (4-
cylinder)
Item Bolt Qty. Nm
1 M10 x 30 3 40
2 M10 x 35 1 50
3 M8 x 20 2 20 → Gearbox to engine (6-cylinder)
5* = upper starter bolt
A: Centring sleeves Item Bolt Qty. Nm
1 M12 x 67 3 65
2 M12 x 90 1 65
3 M12 x 80 1 65
4 M10 x 45 3 45
5 M10 x 135 1 45
5 * M12 x 130 1 65 Page 3 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141329.xml?xsl=2

→ Gearbox/engine assembly mountings (6-
cylinder) 1) Replace bolt Item Bolt Qty. Nm
1 M10 x 35 3 40
2 M8 x 20 2 20 Component Nm
Engine speed sender -G28 10
Clutch slave cylinder to
gearbox 1) 23
Heat shields over drive
shafts to gearbox 23
Selector joint to gearbox 1) 23
Push rod to gearbox 40
Propshaft to gearbox 55
Heat shield for propshaft to
Torsen differential cover 25
Bracket for noise insulation
to body 10 Page 4 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141329.xml?xsl=2