Table of contents: Clutch release mechanism ↓ Removal and installation the clutch… ↓
Clutch release mechanism
1. Ball joint: 25 Nm; lubricate the clutch release lever support "arrow A" with grease -G 000 100-.
2. Intermediate element: replace if damaged.
3. Spring latch: hang on the clutch release lever.
4. Clutch release bearing: do not rinse, just wipe clean; replace bearings that are making loud noise; the bearing retaining tabs must engage in the clutch release lever. Lubricate the mating surface of the clutch release lever with solid lubricant -G 000 150-. If necessary, remove grease from the surface of the guide sleeve "arrow B". Degrease the clutch release bearing mount on the guide sleeve. Release bearing up to 02.2008: inner diameter "arrow B": 34 mm; check the release bearing. Release bearing with oblique thrust washer, from 02.2008: inner diameter "arrow B": 36 mm; check the release bearing with the oblique thrust ring.
5. Clutch release lever: remove any remaining grease from the clutch release lever; lubricate the mating surface of the clutch release bearing "arrow C" with solid lubricant -G 000 150-.
6. Bolt: 8 Nm, 2 pcs.; install with fixing agent -AMV185 101 A1-.
7. Safety plate for guide bushing. Absent since 02.2008. Absent when installing a new guide bushing.
9. Guide sleeve: remove grease from the guide sleeve "arrow D" - degreased clutch release bearing mount on the guide sleeve. Guide bushing up to 02.2008: "arrow D" diameter: 34 mm; when replacing, install without the locking plate. Guide bushing from 02.2008: installed if there is a release bearing with an oblique thrust ring; "arrow D" diameter: 36 mm; installs without a locking plate.
10. Clutch slave cylinder: after removal, do not press the clutch pedal; follow the procedure when pumping; when installing, press down so that the mounting screw can be installed.
10. KP.
Checking the release bearing before 02.2008.
The release bearing with the detached plastic ring "1" must be replaced. Traces of wear "arrow 2" on plastic ring "1" deeper than 0.8 mm - release bearing "3" must be replaced.
Checking the release bearing with an oblique thrust ring "1" - from 02.2008, various designs
Oblique thrust ring "1" with enveloping track "Arrow A";
Oblique thrust ring "1" without track, new;
Oblique thrust ring "1" with separate grooves "B" of the working release bearing.
Examination
The oblique thrust ring of release bearing "1" may have axial clearance and radial runout. The oblique thrust ring "1" in the release bearing "2" can be deflected in all directions (floating function). The beveled thrust washer is practically not secured if the clutch release bearing is not in contact with the clutch. Wear marks "arrow A" or dimples "B" deeper than 0.8 mm - the release bearing must be replaced.
Release bearing lubrication
Noise when pressing the clutch pedal. Lack of lubrication in the support areas of the clutch release bearing "arrow" can lead to a cracking sound when the clutch is engaged. Apply a sufficient amount of solid grease -G 000 150- to the clutch release bearing "arrow" bearings. A thin layer of grease is not sufficient. Remove grease from the surface of the guide sleeve - degrease the clutch release bearing mount on the guide sleeve.
Removal and installation the clutch release lever together with the release bearing and guide sleeve
Remove the clutch release lever "1" with the release bearing "2" and the retaining spring "3". Unscrew the bolts "4" and remove the safety plate "5" (if available) and guide sleeve "6". If present, remove old grease from clutch release lever "1", release bearing "2" and guide sleeve "6".
Installation
Clean and install guide bushing "6" and, if present, lock plate "5". Lock plate "5" will fall out when installing a new guide bushing "6". Clean the threads of bolts "4" with a wire brush. Apply thread sealant "AMV 185 101 A1" to the bolts, install them and tighten to the specified torque. Fix the clutch release bearing "2" and the retaining spring "3" in the clutch release lever "1" and install them together.
(The original article is available on the online resource: AudiManual)