1999 AUDI A4 transmission

30-19


11 -
Guide sleeve
Before removing and installing, cover input
shaft splines with shrink-tube to protect
seal
12 -
O-ring Always replace
13 -
Intermediate piece
14 -
Ball pivot pin 25 Nm (18 ft lb)Lubricate with MoS2 grease
15 -
Transmission
Pa
ge 4 of 13 Clutch release mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.30.2

30-20


Fig. 1 Installing clutch slave cylinder
- Before installing, coat contact surface of clutch release lever plunger
with thin layer of copper grease, e.g. Z 381 351 TE.
- Before installing clutch slave cylinder in transmission, coat boot area -
a- with G 052 150 A2 lithium grease.
- Guide clutch slave cylinder into bore of transmission housing without
large sideways deviation from direction of motion of plunger.

Notes: - Attach bracket -3- for pressure line -1-.
If clutch slave cylinder -4- is inserted crooked, there is a possibility that
the plunger will be inserted past the clutch release lever. Pre-load the clutch slave cylinder enough so that the mounting bolt
can be easily installed.
- Install mounting bolt -2-.
- Install hex bolt with D 185 400 A2 locking fluid and tighten to 25 Nm
(18 ft lb).
If socket-head bolt is used, it is self-locking: always replace and tighten
to 20 Nm (15 ft lb).
Pa
ge 5 of 13 Clutch release mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.30.2

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 been burned out, thoroughly
clean the bellhousing, flywheel and parts of the
engine facing the transmission to reduce the
smell of burnt clutch.
Pa
ge 7 of 13 Clutch release mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.30.2

30-22


- Remove transmission to work on clutch Page
34
-18
.
A - Color marking on dual-mass flywheel
White color marking -A- on dual-mass
flywheel must line up with white color
marking -B- on pressure plate (if present)
B - Color marking on pressure plateWhite color marking -A- on dual-mass
flywheel must line up with white color
marking -B- on pressure plate (if present)
Pa
ge 8 of 13 Clutch release mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.30.2

30-26


Special tools and equipment
Position of clutch plate: spring pack (coil springs) or marking
"Getriebeseite" facing pressure plate and transmission.
Clutch lining and contact surface of pressure plate must make full contact
with flywheel before bolts are inserted. Fig. 1 Centering clutch plate and removing and installing
pressure plate
3067 flywheel retainer 3176 centering mandrel
- When installing on 2.8 Liter 5V 142 kW engine (or 2.8 Liter 128 kW
engine if installed), make sure white color marking on dual-mass
flywheel lines up with white color marking on pressure plate when
assembling.
- Loosen and tighten bolts in stages and in diagonal sequence.
Final tightening torque: 22 Nm (16 ft lb).
- Reverse position of 3067 flywheel retainer when removing.
- Use 3176 centering mandrel to center clutch plate.
Pa
ge 12 of 13 Clutch release mechanism, servicin
g
11/19/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.TM01.30.2