transmission AUDI S4 2000 B5 / 1.G 01E Transmission Clutch Mechanism Service Workshop Manual

30-1


Clutch mechanism, servicing

Note:

For vehicles with coded radio, obtain and note
the radio code.
Disconnect battery Ground strap with the
ignition switched off.
Lubricate all bearings and contact surfaces with
G 052 142 A 2 polycarbamide grease.
Before working on pedal cluster, remove cover
below dash panel:

Repair Manual, Body Interior, Repair Group
68


Make sure that no brake fluid escapes into the
footwell, the plenum chamber or onto the
transmission 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.
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30-13


6 -
Hex socket head bolt, 20 Nm
7 -
Pin
8 -
Master cylinder
With plug-in connection for hose/line
assembly Removing and installing Page 30
-17
9 -
Seal
Must not be removed
10 -
Retaining clip Pull out retaining clip to disconnect line
Page 30
-18

11 -
Transmission
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30-14


12 -
Plastic slave cylinder
Do not operate clutch pedal after slave
cylinder has been removed Brake fluid must not be allowed to get onto
the transmission Lightly grease to install Fig. 1When installing push in until the securing
bolt can be fitted. With plug-in connection for hose/line
assembly Disconnecting hose/line assembly Fig. 2Follow correct sequence of work when
bleeding Page 30
-25
.
13 -
Bleeder valve
Tighten to 4.5 NmFollow correct sequence of work when
bleeding Page 30
-25

A broken off bleeder valve can be removed
using a 3mm hex socket wrench
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30-15


14 -
Dust cap
15 -
Retaining clip
Pull out retaining clip to disconnect line
Fig. 2

16 -
Bracket
Secured to transmission
17 -
Hex socket head bolt 20 Nm
18 -
Nut 2 Nm
19 -
Seal
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30-16


Fig. 1 Installing clutch slave cylinder
- Coat area -a- of collar with lithium grease G 052 150 A2 before
installing slave cylinder into transmission housing.
- Lightly coat contact surface for plunger to clutch release lever with
copper grease, e.g. Z 381 351 TE.

Removing
Installing Fig. 2 Disconnecting line and clutch slave cylinder
- To disconnect line, use a screwdriver to pry out retaining clip -A- so
that it clicks. Line can then be pulled out.
- Press in retaining clip -A- as far as it will go.
- Push line into slave cylinder until it engages audibly.
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30-18


Note: - Unscrew both nuts -A-.
- Lift E-box off studs at the rear and then pull it out of securing point -B-.
In the following procedures, make sure that no brake fluid escapes
into the plenum chamber or onto the transmission 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.

- Clamp supply hose -A- from brake fluid reservoir using special tool
3094. Pull hose off master cylinder and plug hose.
- Remove rubber grommet for compensation hose above connecting line
from transverse wall.
- Pry out retaining clip -C- using a screwdriver and pull line -B- out
slightly.
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30-25

Clutch system, bleeding


Special tools, testers and auxiliary items

Brake filling and bleeding appliance V.A.G 1238
B
or
Brake filling and bleeding appliance V.A.G
1869

Note:
First open bleeder valve before switching on
bleeding appliance.
When performing the following steps, make
sure that no brake fluid escapes onto the
transmission.
The clutch system must be bled after
performing work on hydraulic clutch
mechanism.
Top-up brake fluid reservoir to "max." marking
with brake fluid before bleeding clutch system.

- Pull clutch pedal back to its normal position.
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