2000 AUDI A6 gearbox

Installation is carried out in the reverse
order; note the following:
‒ → Insert the master cylinder so that
seal -1- and the washer lie behind
the mounting bracket and tighten
bolts -2- to 20 Nm.
‒ Press connection pipe -3- with guide
-arrow A- into recess -arrow B- on
mounting bracket. A second mechanic is required for the next
step.
‒ → Slide the complete pedal cluster
forwards towards the cross panel,
insert the bolt -arrow 3- and tighten it finger tight. The second mechanic should guide the pipe into the master cylinder starting from the plenum
chamber. Old version with internal torx socket-head bolts:
‒ → Tighten the retaining bolts for the
brake servo -arrows- to 25 Nm.
New version with external torx socket-
head bolts: ‒ → Tighten the retaining bolts for the Page 4 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2

brake servo -arrows- to 25 Nm. ‒ → Screw in the bolt for the brake
fluid reservoir -1- and attach the
connector for fluid level.
All models: ‒ → Tighten the hexagon socket head
bolt -arrow B- for securing pedal
cluster to dash panel crossmember
to 25 Nm. ‒ Connect clutch pedal to master Page 5 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2

cylinder. Clip pin onto clutch pedal.
‒ → Press retaining clip -C- home.
‒ Push pipe -B- into master cylinder
until it audibly locks in place.
‒ Insert rubber grommet -D- over
connection pipe/supply hose -A- into
the cross panel.
‒ Push supply hose -A- for the brake
fluid reservoir on to limit stop.
‒ Remove special tool 3094.
‒ After installing the master cylinder,
bleed the clutch system =>Page 30-30.
‒ If fitted, check the adjustment of the
clutch pedal switch -F 36 => Page
30-8.
‒ Install storage compartment for
driver's side: => General Body Assembly, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage compartment Page 6 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141312.xml?xsl=2

Servicing clutch mechanism Bleeding clutch system Special tools, testers and auxiliary items required
◆ Brake filler and bleeder unit V.A.G
1869
or
◆ Brake filler and bleeder unit V.A.G
1238 B
Notes:
◆ The clutch system must be bled after performing work on the hydraulic clutch mechanism.
◆ Top up brake fluid reservoir to "max"
marking with brake fluid before
bleeding clutch system.
◆ Open the bleeder valve before
switching on the bleeder unit.
◆ When performing the following steps,
ensure that no brake fluid escapes
onto the gearbox.
‒ Pull clutch pedal back to its normal rest position.
‒ Connect brake filler and bleeder unit
V.A.G 1238 B or V.A.G 1869, but do
not switch on at this stage.
‒ Remove shield, if fitted, from
underneath gearbox. ‒ → Connect bleeder hose -A- to slave
cylinder (arrow) and open bleeder
valve.
‒ Connect bleeder hose to pressure
hose of fluid collector bottle.
‒ Switch on the bleeder appliance and
allow about 100 cm3 of brake fluid to
drain out.
‒ Working pressure 2.5 bar
Note:
Ensure bleeder hose is correctly fitted during
bleeding operation.
‒ Close bleeder valve and tighten to 4.5
Nm.
‒ Depress clutch pedal several times
after completion of bleeding process.
‒ Bleed again if necessary. Page 1 of 15-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141313.xml?xsl=2

Servicing clutch release mechanism Servicing clutch release mechanism 1.Gearbox 2.Ball stud
◆ Tighten to 25
Nm
◆ Lubricate with MoS2-grease 3.Intermediate piece 4.Dished washer
◆ Smaller
diameter
(convex side)
to guide
sleeve
5.O-ring
◆ Replacing
6.Replace input shaft sealing ring
◆ is available
as a
replacement
part together with the guide sleeve -Item
7-
◆ Pack space
between
sealing and
dust lips half-
full with
sealing grease G 052 128 A1.
7.Guide sleeve ◆ Is available as
a replacement
part together
with the
sealing ring -
Item 6-
◆ Installation
position: The
oil drain bore
points
downwards.
◆ Before removing/fitting in order to
protect the
sealing ring -
Item 6- pull
shrink-fit hose
over the
splines on the
input shaft
8.Retaining spring Page 1 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

◆ Secure to clutch release lever
9.Torx socket head
bolt - 35 Nm
◆ Self-locking
◆ Replacing
10.Clutch release
lever
◆ Before
installing,
coat contact
surface of
clutch slave
cylinder push
rod with
copper grease, e.g. Z 381 351 TE. 11.Release bearing ◆ With or
without
plastic ring, depending on version
=>Fig.1
◆ Cement
detached plastic ring => Fig.1
◆ Do not wash
out bearing,
only wipe
◆ Replace
noisy
bearings
◆ Engage
retaining
latches at the
release
bearing in
contact
release lever 12.Slave cylinder
◆ Do not Page 2 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

operate clutch
pedal after slave cylinder has been
removed.
◆ Removing => Fig.2
◆ Detach from
hose/pipe
assembly =>
Fig.3
◆ Installing =>
Fig.4 and
Fig.5
◆ When
installing, press in slave cylinder far
enough so
that securing
bolt can be
fitted easily.
◆ Follow
correct work
sequence
when
bleeding =>
Page 30-30
◆ Tighten bleed valve to 4.5
Nm 13.Hexagon socket-head bolt - 23Nm
◆ Slave
cylinder to
gearbox
◆ Self-locking
◆ Always
replace
14.Bracket
◆ For hose/pipe assembly
◆ Attached
together with
the slave cylinder to the gearbox
◆ Installing =>
Fig.5
15.Push rod
◆ Lubricate end of push rod
with copper grease, e.g. Z 381 351 TE Page 3 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2

→ Fig.1 Repairing release bearing with plastic ring
In the case of release bearings with plastic
ring it is possible that the plastic ring
detaches from the release bearing during
removal of the gearbox. This does not signify
that replacement of the release bearing is
necessary.
‒ Cement the loose plastic ring to the
bearing ring with adhesive AMV 195 KD1
01 before installing the gearbox.
Three rectangular lugs -arrows- on the plastic
ring engage into recesses in the bearing ring.
Note:
If the plastic ring has become embedded deeper
than 0.5 mm in the bearing surface, the bearing
ring must be replaced. → Fig.2 Removing slave cylinder Page 4 of 65-Speed Manual Gearbox 01A 4WD4.3.2014vw-wi://rl/A.en-GB.4B-S-S01AA.wi::21141314.xml?xsl=2