Overview - Clutch Release Mechanism

Fig 1: Clutch Release Mechanism Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

1. Ball Stud
   • 25 Nm
   • Apply Grease For Clutch Disc Shaft SplinesG 000 100 to the clutch release lever bearing area -arrow A-.
2. Intermediate Piece
   • Replace if damaged
3. Spring
   • Engage in the clutch release lever
4. Release Bearing
   • Different versions
   • Allocate correct components .
   • Do not wash it, just wipe it off.
   • Replace loud bearings
   • Let the securing tangs on the release bearing lock in place on the release lever
   • Removing and installing. Refer to CLUTCH RELEASE MECHANISM, SERVICING .
     NOTE:

     Apply plenty of Grease G 000 150 to the clutch release lever bearing area. Refer to Fig 4.

     If equipped, remove any grease inside the bearing area for the guide sleeve -arrow B- -release bearing mounting on the guide sleeve must be free of grease

     Release Bearing Through 02/2008

     • Inner diameter -arrow B- : 34 mm
     • Release Bearing, Checking. Refer to Fig 2

     Release Bearing with Pressure Ring - From 02/2008

     • Inner diameter -arrow B- : 36 mm
     • Check the release bearing with the pressure ring. Refer to Fig 3
5. Clutch Release Lever
   • Different versions
   • Allocate correct components .
   • Remove the old grease from the release lever.
   • Lubricate the bearing area for the release bearing -arrow C- again with Grease G 000 150.
   • Removing and installing. Refer to CLUTCH RELEASE MECHANISM, SERVICING .
6. Bolt
   • 8 Nm
   • different bolt lengths
   • Allocate correct components .
   • Quantity: 2
   • Insert with Locking FluidAMV 185 101 A1
7. Securing Plate
   • For guide sleeve
     NOTE:

     Deleted from 02/2008

     also deleted when installing a new guide sleeve -item 8-

     Allocate correct components .

8. Guide Sleeve
   • Different versions
   • Allocate correct components .
   • Remove any grease on the guide sleeve -arrow D-

     Guide Sleeve Through 02/2008

     • Diameter -arrow D- : 34 mm
     • When replacing, install without the locking plate, refer to -item  7- "Securing Plate" (See Fig 1)

     Guide Sleeve From 02/2008

     • Installed on the release bearing with pressure ring. Refer to Fig 3
     • Diameter -arrow D- : 36 mm
     • Installed with the locking plate; refer to -item  7- "Securing Plate" (See Fig 1)
9. Clutch Slave Cylinder
   • Removing and installing. Refer to CLUTCH SLAVE CYLINDER, REMOVING AND INSTALLING
   • Do not actuate after removing the clutch pedal
   • Pay attention to the work sequence when bleeding. Refer to CLUTCH MECHANISM, BLEEDING
   • When inserting, push in so far until the bolt can be installed.
10. Transmission

Fig 2: Checking Release Bearing With Plastic Ring Attached

Courtesy of AUDI OF AMERICA, LLC

• Release bearing with worn-down plastic ring -1- has to be replaced.
• If the running surface -arrow 2- on the plastic ring -1- is worn deeper than 0.8 mm, the release bearing -3- must be replaced.

Fig 3: Check Release Bearing with Pressure Ring - from February 2008

Courtesy of AUDI OF AMERICA, LLC

Different Versions:

• Pressure ring -1- with surrounding running surface -Arrow A-
• Pressure ring -1- without running surface in new condition
• Pressure ring -1- with discrete indentations -B- from release bearing running on it

Check:

• The pressure ring for the release bearing -1- may have axial and radial play.
• The pressure ring -1- can tip on all sides inside the release bearing -2-.
• If the running surface -Arrow A- or the indentations -B- on the pressure ring -1- are worn deeper than 0.8 mm, then the release bearing must be replaced.
• The pressure ring is almost loose when the release bearing is not touching the clutch.

Fig 4: Lubricating Release Bearing

Courtesy of AUDI OF AMERICA, LLC