oil 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

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

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

‒ 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:
â—† 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.
â—† 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

gearbox and place onto heat shield -2-. ‒ Secure propshaft with wire -arrow- at bracket -3- of fuel lines.
‒ Place drip tray underneath.
‒ Drain gear oil. ‒ → Unbolt cover -A- with Torsen
differential from gearbox cover -B-.
Note:
Shown in illustration with gearbox removed. ‒ Detach spring -C- from drive pinion.
Installing
Installation is carried out in the reverse
order; note the following:
‒ Remove old sealing paste and clean
the sealing surfaces thoroughly.
‒ Apply sealing paste AMV 188 001 02 to sealing surfaces. ‒ → Check that compression spring -
C- is fitted and that dowel sleeves -
arrows- are fitted in gearbox cover -
B- or in cover -A-.
‒ Fit cover -A- and tighten.
‒ Attaching propshaft => Page 39-84.
‒ Top up oil in gearbox and check oil
level in gearbox => Page 34-56.
‒ 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 Page 2 of 35-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141331.xml?xsl=2

â—† V.A.G 1331 Torque wrench
â—† Sealant AMV 188 001 02 Notes:
â—† It is not necessary to remove the
differential to remove the above-
mentioned components => Page 34-74.
â—† Removal is only necessary when
adjustments have to be carried out
=> adjustment overview, Page 39-45.
Removing
‒ Place drip tray V.A.G 1306
underneath the gearbox.
‒ Drain gearbox oil using socket
attachment 3357.
‒ → Secure gearbox in assembly
stand VW 540. Page 2 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

‒ → Detach clutch release lever -A-
with release bearing.
Notes:
â—† Before pulling off guide sleeve, cover input shaft splines with a shrink-fit
hose to protect oil seal.
â—† Removing oil seal from guide sleeve
=> Page 30-32.
‒ Unscrew guide sleeve -B-.
‒ Remove dished washer -C-.
‒ Remove circlip -D- in front of input
shaft ball bearing. ‒ If the ball bearing, input shaft or
gearbox housing is not to be
replaced, note the thickness of the
circlip.
‒ → Pull the input shaft ball bearing
out of the gearbox housing. Page 3 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

input shaft ball bearing.
‒ Then fit dished washer -C-.
‒ Installation position: convex
side towards guide sleeve -B- Notes:
â—† Before fitting guide sleeve, cover
input shaft splines with a shrink-fit
hose to protect oil seal.
â—† Installing oil seal in guide sleeve =>
Page 30-32. ‒ → Fit guide sleeve -B- for release
bearing.
‒ Fit clutch release lever -A- and
release bearing. Page 11 of 115-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141337.xml?xsl=2

(arrows) for the intermediate bearing
and remove the propshaft with the
assembly device.
Note:
Only transport and store propshaft when
extended. Installing Installation is carried out in the reverse
order; note the following:
Notes:
◆ → To avoid imbalance the flanges of the propshaft -arrow A- and of the
rear final drive -arrow B- must be
fitted so that the factory colour
markings or the subsequently made
markings are aligned.
â—† If a new propshaft is installed and if
the factory colour marking on the
flange of the rear final drive is no
longer visible the radial run-out on
the propshaft flange must be
measured => Page 39-87 and the
colour marking on the propshaft
aligned with the new marking on the
flange.
â—† Renew gaskets on flange shafts
(detach protective foil and stick
gasket onto flange shaft).
â—† After removing the propshaft from
the rear final drive, the additional
balance disc (thicker washer) that
may be located between the lock
plate and the bolt head must not be
reinstalled.
â—† It is essential that the locking fluid
remaining in the threads in the
flange shafts on the gearbox and
rear final drive is cleaned out after
removing the propshaft. Otherwise
there is a danger that the new bolts
will seize when they are screwed in
and then shear if they have to be
removed later.
â—† The threaded holes can be cleaned Page 3 of 45-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141363.xml?xsl=2