Clutches - 01a, Awd — Audi A6 C5 (1997-2001)

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: 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. Protect carpet from brake fluid using rags when performing work in footwell.

Pedal cluster, assembly overview

Note. The following list refers to items in (Scheme 1).

Mounting bracket Detach steering column from steering box before removing. See «STEERING»(/audi/a6/c5-1997-2001/remont/steering-column-switches/#steering) .
Pivot pin For clutch pedal and brake pedal Installation position: groove (arrow) toward clutch pedal
Locking clip
Hexagon socket head bolt, 25 Nm
Brake pedal
Clutch pedal Removing and installing, see «CLUTCH PEDAL AND OVER-CENTER SPRING, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd)
Pin Clip onto clutch pedal
Locking clip
Master cylinder Removing and installing, see «MASTER CYLINDER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd)
Hexagon socket head bolt, 20 Nm
Mounting Insert in mounting bracket with over-center spring
Over-center spring Allocation, see parts catalogue Remove and install with clutch pedal, see «CLUTCH PEDAL AND OVER-CENTER SPRING, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd)
Hexagon socket head bolt, 5 Nm Secures clutch and brake pedal pivot pin
Seal
Torxbolt, 25 Nm Also secures the brake master cylinder with brake servo

Scheme 1

Scheme 2

Scheme 2: Removing

Scheme 3

Scheme 4

Remove storage compartment, driver's side. See «DRIVER'S STORAGE COMPARTMENT, REMOVING»(/audi/a6/c5-1997-2001/remont/mirrors/#interior-equipment__drivers-storage-compartment-removing) . NOTE: For the following tasks, make sure the clutch pedal does not press the switch -arrow- out of the holding clamp, since the thread of the switch will be damaged and the switch will have to be replaced. In order to assure sufficiently secure fitting, switch -arrow- must not be installed more than once.
Detach clutch pedal from master cylinder. To do this, unclip pin using a screwdriver arrow -1- and pull out pin arrow -2-.
Press clutch pedal locking 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-center spring.

Installing

Installation is carried out in the reverse order, when doing this note the following

Scheme 5

Scheme 5: Installing

Scheme 6

Align the clutch pedal/brake pedal pivot pin so that it protrudes out of mounting bracket at the clutch pedal side (arrow).
First hook the clutch pedal into the over-center 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.
Check adjustment of vent valve -1- above the clutch pedal as follows: Vent valve -1- must contact clutch pedal -3- completely and must be operated fully. (Scheme 7) Tolerance: Gap measurement -a- between retaining clip and mounting bracket -2- i.e. gap measurement -1- at switch -1- may be a max. of. 0.5 mm. To adjust, hold clamp and turn vent valve -1-.

Scheme 7

Note. In order to assure sufficiently secure fitting, switch must not be installed more than once.

Clutch Pedal Position (CPP) Switch -F194-, removing and installing

Note. Clutch Pedal Position (CPP) Switch -F194- ensures that the engine can only be started with the clutch pedal depressed.

Note. The following list refers to items in (Scheme 8).

Bracket
Cable bracket
Locking clip
Pin Clip onto clutch pedal
Clutch pedal Removing and installing, see «CLUTCH PEDAL AND OVER-CENTER SPRING, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd)
Clip
Bracket for harness connector
Clutch Pedal Position (CPP) Switch -F194- Adjusting, see «CLUTCH PEDAL POSITION (CPP) SWITCH - F194-, ADJUSTING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-pedal-position-cpp-switch)
Clip
Screw and washer assembly, 8 Nm
Securing plate

Scheme 8

Clutch Pedal Position (CPP) switch - F194-, adjusting

Loosen 2 bolts -arrows- somewhat. (Scheme 9)
Have a second technician depress clutch pedal to stop.
Place feeler gauge -A-with selected dimension -a- 3.2 m + 0.2 mm between operating surface of clutch pedal and switch plunger.
Swing switch -B- toward gauge -A- to stop toward feeler gauge -A- and tighten two mounting bolts (arrows) to 8 Nm. (Scheme 9)

Scheme 9

Hydraulic system, general layout

Note. The following list refers to items in (Scheme 10).

Brake fluid reservoir
Supply hose
Hose/pipe assembly For plug-in connections on master cylinder and slave cylinder Disconnecting from master cylinder and installing, see «INSTALLING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd) Disconnecting from slave cylinder, see «DISCONNECTING PIPE FROM CLUTCH SLAVE CYLINDER»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd) Allocation for LHD and RHD vehicles, see parts catalogue
Mounting bracket
Clutch pedal
Hexagon socket head bolt, 20 Nm
Pin
Plastic master cylinder With plug-in connection for hose/pipe assembly Removing and installing, see «MASTER CYLINDER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd) Do not operate after the clutch pedal has been removed
Seal
Retaining clip Pull out retaining clip to disconnect pipe, see «INSTALLING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd)
Transmission
Plastic slave cylinder Do not operate after the clutch pedal has been removed Brake fluid must not be allowed to get onto the transmission Lightly grease before installing. See «REPLACING CLUTCH SLAVE CYLINDER»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd__replacing-clutch-slave-cylinder) . When installing push in until the securing bolt can be fitted. With plug-in connection for hose/pipe assembly Disconnecting hose/pipe assembly, see «DISCONNECTING PIPE FROM CLUTCH SLAVE CYLINDER»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd) Observe work sequence when bleeding. See «CLUTCH RELEASE MECHANISM, SERVICING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-release-mechanism-servicing) .
Bleeder valve/slave cylinder Tighten to 4.5 Nm Observe work sequence when bleeding. See «CLUTCH RELEASE MECHANISM, SERVICING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd__clutch-release-mechanism-servicing) . A bleeder valve that has been broken off can be unscrewed with a 3 mm socket wrench.
Dust cap
Retaining clip Pull out retaining clip to disconnect pipe. See «DISCONNECTING PIPE FROM CLUTCH SLAVE CYLINDER»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd) .
Bracket Secured to transmission
Hexagon socket head bolt, 20 Nm
Nut, 2 Nm
Seal

Scheme 10

Replacing clutch slave cylinder

Before installing clutch slave cylinder into transmission housing, coat boot area -a- with G 052 150 A2 lithium grease.
Coat contact surface of clutch release lever plunger with a thin layer of copper grease, e.g. Z 381 351 TE

Removing

To disconnect pipe, use a screwdriver to lever out retaining clip -A- so that it clicks. The pipe can then be pulled out.

Scheme 11

Press in retaining clip -A- as far as it will go.
Push pipe into slave cylinder until it engages audibly

Required tools and equipment

Hose clamp 3094

Scheme 12

If installed, remove cover above plenum chamber.
Disconnect battery Ground (GND) strap with ignition switched off.

Note. When performing the following steps, make sure that no brake fluid escapes into the plenum chamber or onto the transmission below. Protect carpet from brake fluid using rags when working in footwell.

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Clamp supply hose -A- from brake fluid reservoir using special tool 3094. Pull hose off master cylinder and plug hose. (Scheme 14)
Remove grommet from bulkhead via connection pipe for supply hose.
Lever out retaining clip -C- using a screwdriver and pull pipe -B- out slightly.
Remove bolt -1- and swing brake fluid container -2- enough to the right that the socket head Torx bolt -3- can be removed. (Scheme 15)
Remove the second socket head Torx bolt -4-.
Remove storage compartment on driver's side. See «DRIVER'S STORAGE COMPARTMENT, REMOVING»(/audi/a6/c5-1997-2001/remont/mirrors/#interior-equipment__drivers-storage-compartment-removing).
Detach clutch pedal from master cylinder. To do this, unclip pin using a screwdriver -arrow 1- pull out pin -arrow 2- and carefully press clutch pedal through. NOTE: For the following steps, make sure clutch pedal does not press switch -1- out of the retaining clip, since this damages the thread of the switch and the switch will have to be replaced. (Scheme 17) In order to assure sufficiently secure fitting, switch must not be installed more than once.
Remove bolts for clutch slave cylinder -arrow 2- and for mounting bracket -arrow 3-. (Scheme 17)
Pull complete pedal assembly slightly toward passenger compartment and remove clutch master cylinder -4-.

Installation is carried out in the reverse order, when doing this note the following

Scheme 17

Scheme 17: Installing

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Insert clutch master cylinder so that seal -1- with washer contact mounting bracket at rear and tighten bolts -2- to 20 Nm. (Scheme 18)
Press connecting pipe -3- with guide -arrow A- into recess -arrow B- at mounting bracket. A second technician is needed for the following work step.
Slide complete pedal assembly toward transverse wall toward front, insert bolt -arrow 3- and tighten by hand. (Scheme 19) At the same time, the second technician must guide the pipe from the plenum chamber into the clutch master cylinder.
Tighten mounting bolts for brake booster -3- and -4- to 25 Nm. (Scheme 20)
Tighten mounting bolt for brake fluid container -1-.
Press in retaining clip -C- as far as it will go. (Scheme 21)
Push pipe -B- into master cylinder until it engages audibly.
Insert rubber grommet into bulkhead as far as it will go via connection pipe for supply hose -A-. (Scheme 21)
Push supply hose -A- from brake fluid reservoir on as far as it will go.
Remove special tool 3094.
Tighten socket-head bolt -arrow- to 25 Nm to secure pedal assembly to instrument panel carrier.
Connect clutch master cylinder to clutch pedal. Engage bolt lock in clutch pedal.
Bleed clutch system after installing clutch master cylinder. See «CLUTCH SYSTEM, BLEEDING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd).
Check adjustment of vent valve -1- above the clutch pedal as follows: Vent valve -1- must contact clutch pedal -3- completely and must be operated fully. (Scheme 23) Tolerance: Gap measurement -a- between retaining clip and mounting bracket -2- (i.e. gap measurement -1-) at switch -1- may be a max. of. 0.5 mm. To adjust, hold clamp and turn vent valve -1-.
Install driver's side storage compartment. See «DRIVER'S STORAGE COMPARTMENT, REMOVING»(/audi/a6/c5-1997-2001/remont/mirrors/#interior-equipment__drivers-storage-compartment-removing).

Special tools and equipment

VAG1869 brake filler/bleeder unit

Scheme 22

Bleeding

Note. First open bleeder valve, before switching on brake filler/bleeder unit. For this work step, make sure no brake fluid leaks onto transmission. Bleed clutch system after working on hydraulic clutch mechanism. Top off brake fluid reservoir to "MAX" mark before bleeding clutch system.

Scheme 23

Scheme 23: Bleeding

Pull clutch pedal back to rest position.
Connect VAG1238B or VAG1869 brake filler/bleeder unit but do not switch on yet.
Connect bleeder hose -A- to clutch slave cylinder (arrow) and open bleeder valve.
Connect bleeder hose to pressure hose of collector bottle.
Now switch on brake filler/bleeder unit and bleed approx. 100 cm3 of brake fluid. Work pressure: 2.5 bar positive pressure NOTE: While bleeding, make sure bleeder hose remains correctly routed.
Close bleeder valve and tighten to 4.5 Nm.
Depress clutch pedal several times after completion of bleeding process.
Bleed system again if necessary.

Clutch release mechanism, servicing

Note. The following list refers to items in (Scheme 26).

Transmission
Ball stud Tighten to 25 Nm Lubricate with MoS2 grease
Intermediate piece
Dished washer Smaller diameter (convex side) to guide sleeve
O-ring Replace
Input shaft oil seal Pull out of guide sleeve with oil seal extractor lever VW 681 Knock in onto stop with fitting sleeve VW 192
Guide sleeve Before removing and installing, cover input shaft splines with a shrink-fit hose to protect oil seal.
Retaining spring Secure to clutch release lever
Clutch release lever Before installing, coat contact surface of clutch slave cylinder plunger with a thin layer of copper grease, for example 381 351 TE
Torx socket head bolt, 35 Nm Self-locking Replace
Release bearing Do not wash-out bearing, only wipe Replace noisy bearings Allow retaining tabs on release bearing to engage in release lever
Plunger Grease end of plunger with copper grease, for example 381 351 TE
Bracket Secured to transmission along with slave cylinder
Hexagon socket head bolt, 20 Nm Self-locking Replace
Slave cylinder Do not operate clutch pedal after removing Removing and installing, see «REMOVING»(/audi/a6/c5-1997-2001/remont/clutches-manual-hydraulic/#clutches-01a-awd) Pretension slave cylinder enough that mounting bolt can be inserted easily.

Scheme 24

Scheme 25

Scheme 25: Installing clutch slave cylinder

Scheme 26

Coat contact surface of clutch release lever plunger with a thin layer of copper grease, for example Z 381 351 TE
Before installing clutch slave cylinder into transmission housing, coat boot area -a- with G 052 150 A2 lithium grease.
Engage bracket for pressure line -3- into clutch slave cylinder -4- and bolt to transmission together with clutch slave cylinder. (Scheme 28)
Insert clutch slave cylinder straight without sideways movement of the plunger into take-up hole of transmission housing. NOTE: If clutch slave cylinder -4- is inserted crooked, there is a possibility that the plunger will be inserted past the clutch release lever. (Scheme 28) Pre-tension clutch slave cylinder enough so that mounting bolt can be easily inserted. Remove mounting bolt -2-. (Scheme 28)

Clutch, servicing

Note. Observe general repair instructions. See REPAIR INSTRUCTIONS, GENERAL . Replace clutch plates and pressure plates with damaged or loose rivets. Select the correct clutch plate and pressure plate according to engine code. 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. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Excess grease must be removed. Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced. If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the transmission to reduce the smell of burnt linings.

Note. The following list refers to items in (Scheme 29).

Remove transmission to work on the clutch. See «5 SPD. MANUAL TRANSMISSION 01A - TRANSMISSION REMOVAL»(/audi/a6/c5-1997-2001/remont/manual-trans/#5-spd-manual-transmission-01a-transmission-removal) - Colored marking on dual-mass flywheel If there is a white marking -A- on dual-mass flywheel it must coincide with white marking -B- on pressure plate. - Colored marking on pressure plate If there is a white marking -A- on dual-mass flywheel it must coincide with white marking -B- on pressure plate.