Clutch Release Mechanism Overview

Fig 1: Clutch Release Mechanism Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

1. Ball Studs
   • 25 Nm
   • Lubricate the clutch release lever bearing surface -arrow A- with grease for clutch disc shaft splines G 000 100.
2. Intermediate Piece
   • Replace if damaged
3. Spring
   • Engage in the clutch release lever
4. Release Bearing
   • Different versions
   • Allocation.
   • Do not wash it, just wipe it off.
   • Replace loud bearings
     NOTE:

     Coat the clutch release lever bearing area with adhesive lubricating paste G 000 150, refer to Fig 4

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

   • Let the securing tangs on the release bearing lock in place on the release lever
   • Removing and installing, refer to CLUTCH RELEASE LEVER WITH RELEASE BEARING AND GUIDE SLEEVE 

     Release Bearing through 02.2008

     • Inner diameter -arrow B- : 34 mm
     • Release bearing, checking, refer to Fig 2

     Release Bearing with pressure ring - from February 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
   • Allocation.
   • Remove the old grease from the release lever.
   • Lubricate the release lever bearing surface -arrow C- with adhesive lubricating paste G 000 150.
   • Removing and installing, refer to CLUTCH RELEASE LEVER WITH RELEASE BEARING AND GUIDE SLEEVE 
6. Bolt
   • 8 Nm
   • Different bolt lengths
   • Allocation.
   • Quantity: 2
   • Insert with locking fluid AMV 185 101 A1
7. Securing Plate
   • For guide sleeve
     NOTE:

     Deleted from 02.2008

     Also deleted when installing a new guide sleeve CLUTCH RELEASE LEVER WITH RELEASE BEARING AND GUIDE SLEEVE .

     Allocation.

8. Guide Sleeve
   • Different versions
   • Allocation.
   • 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 CLUTCH RELEASE LEVER WITH RELEASE BEARING AND GUIDE SLEEVE .

     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 CLUTCH RELEASE LEVER WITH RELEASE BEARING AND GUIDE SLEEVE .
9. Clutch Slave Cylinder
   • Removing and installing, refer to [For engine(s) CAUA] Removal and Installation
   • Do not actuate after removing the clutch pedal
   • Pay attention to the work sequence when bleeding; refer to [For engine(s) CAUA] General Information
   • 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: Checking 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