1996 Audi A6 Quattro
CLUTCH - AWD 1995-96 Clutch
CLUTCH - AWD
1995-96 Clutch
DESCRIPTION
Clutch is single-plate, dry-disc type. Pressure plate is diaphragm spring type. Some models are equipped with a
dual-mass flywheel. Bearing is operated by a clutch master cylinder, slave cylinder, push rod and release lever.
HYDRAULIC CLUTCH BLEEDING
Attach hose to bleeder fitting located on clutch release cylinder, next to hydraulic line. Submerge other end of
hose in container half full of clean brake fluid. Fill reservoir with DOT 3 fluid. Open bleeder fitting. Have
assistant press clutch pedal to full release position. Close bleeder fitting. Release clutch pedal. Repeat until air
bubbles no longer emerge from hose. Refill reservoir.
ADJUSTMENTS
CLUTCH PEDAL
NOTE: If clutch pedal is correctly adjusted but fails to return properly, inspect for
seized pedal bushing or jammed return spring.
When engaged, clutch pedal should be .39" (10.0 mm) above brake pedal. If adjustment is required, loosen
clutch master cylinder push rod locking nut, and rotate push rod until correct clutch pedal height is obtained.
Ensure pedal return spring holds clutch pedal against stop pad.
DRIVE SHAFT
1. Remove front exhaust pipe and catalytic converter. Remove front crossmember and heat shield. Remove
remaining exhaust pipe. Remove drive shaft crossmember. Loosen drive shaft mounting bolts.
2. Mount Drive Shaft Alignment Fixture (3139 ) to drive shaft. See Fig. 1 . Tighten drive shaft alignment
fixture plastic nuts. Remove center drive shaft bearing securing bolts and shims. Measure gap between
vehicle body and center bearing mounting bracket. Install appropriate shims and install bolts. See DRIVE
SHAFT SHIMMING .
3. Push drive shaft to furthest rearmost position. Using center drive shaft bearing bracket as a guide, mark
drive shaft position on vehicle body. Push drive shaft to furthest frontmost position and mark drive shaft
position on vehicle body. Move drive shaft so that center bearing bracket is positioned between marks.
DRIVE SHAFT SHIMMING
Measured Distance - In. (mm) Shim Thickness - In. (mm)
0-.12 (0-3) No Shims
.12-.20 (3.1-5) .08 (2)
.20-.28 (5.1-7) .16 (4)
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1996 Audi A6 Quattro
CLUTCH - AWD 1995-96 Clutch
.28-.35 (7.1-9) .24 (6)
.35-.43 (9.1-11) .32 (8)
.43-.51 (11.1-13) .39 (10)
Fig. 1: Installing Drive Shaft Alignment Fixture (3139) To Drive Shaft
Courtesy of AUDI OF AMERICA, INC.
REMOVAL & INSTALLATION
NOTE: On models with theft protection system, obtain stereo security code from
vehicle owner before disconnecting battery cable.
CLUTCH ASSEMBLY
Removal
1. Remove battery cover. Disconnect negative battery cable. Remove upper transaxle-to-engine mounting
bolts. Remove intake air ducting. Disconnect vehicle speed sensor and back-up light connectors. Remove
all electrical connectors from transaxle.
2. Remove torque arm mounting bolts. See Fig. 2 . Attach Engine Support Bridge (10-222A ) to left engine
bracket. Support engine. Raise and support vehicle. Remove engine splash shield and bracket. Remove
transaxle crossmember. Remove exhaust pipe and catalytic converter. Remove shift rod.
3. Disconnect automatic seat belt tension cables at transaxle. Remove inner CV joint heat shields. Remove
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1996 Audi A6 Quattro
CLUTCH - AWD 1995-96 Clutch
drive shaft. Disconnect left and right axle shafts at transaxle. See the AXLE SHAFT article in DRIVE
AXLES. If equipped, remove right heat shield. Remove starter wiring and starter.
4. Support transaxle using transmission jack. Remove left and right transaxle-to-subframe mounting bolts.
Remove slave cylinder with fluid line attached. Remove lower transaxle-to-engine mounting bolts.
Remove transaxle.
5. If reusing pressure plate, index mark position of pressure plate on flywheel. Loosen pressure plate
mounting bolts evenly in a crisscross pattern. Remove clutch assembly.
NOTE: Pressure plate has a protective grease coating. Remove contact surface grease
only. Service life will be shortened if remaining portions of pressure plate
protective grease are removed.
Fig. 2: Identifying Torque Arm
Courtesy of AUDI OF AMERICA, INC.
Inspection
1. Check flywheel for warpage, burn marks, grooves and excessive dowel pin wear. If necessary, resurface
flywheel and replace dowel pins.
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1996 Audi A6 Quattro
CLUTCH - AWD 1995-96 Clutch
2. Check clutch pressure plate for burn marks and grooves. Using a straightedge and a feeler gauge, measure
taper of pressure plate surface. Maximum taper is .012" (.30 mm). Check for grooves on diaphragm
spring ends. Maximum groove depth is 1/2 thickness of spring end. Replace if necessary.
3. Check clutch disc for excessive wear, loose rivets, worn springs and oil contamination. Measure clutch
disc runout using dial indicator with disc mounted on arbor between centers. Measure runout .098" (2.50
mm) from outer edge of clutch disc. Maximum runout is .020" (.50 mm). Replace clutch disc if necessary.
Installation
1. Ensure clutch disc slides freely with no radial play on input shaft. If equipped with a dual mass flywheel,
clutch disc long hub end should face pressure plate. If not equipped with dual mass flywheel, clutch disc
spring cage should face pressure plate. Lubricate input shaft splines with molybdenum grease.
2. Align pressure plate index marks. Use Clutch Disc Aligner (10-213 ) to center disc. Install NEW "O" ring
and flywheel bolts. Install NEW clutch release bearing guide sleeve Torx bolts. Adjust drive shaft. See
DRIVE SHAFT under ADJUSTMENTS. To complete installation, reverse removal procedure. Bleed
hydraulic system. See HYDRAULIC CLUTCH BLEEDING .
CLUTCH MASTER CYLINDER
Removal
Disconnect and plug fluid lines. Remove circlip and clevis pin. See Fig. 4 . Separate push rod from clutch pedal.
Remove master cylinder mounting bolts. Remove master cylinder.
Installation
To install master cylinder, reverse removal procedure. Ensure secondary cup sealing lips face piston and
primary cup sealing lips face spring. Bleed master cylinder. See HYDRAULIC CLUTCH BLEEDING .
CLUTCH RELEASE BEARING
Removal
Remove transaxle. Remove cap bolt and 2 retainers at lower edge of release lever. Slide release lever and
bearing out of bellhousing.
Inspection
Check clutch release bearing for looseness and noise. If necessary, replace bearing.
Installation
Grease ball head stud located in clutch housing. See Fig. 3 . DO NOT grease clutch release bearing guide
sleeve. DO NOT wash bearing in solvent. Ensure clutch release lever contacts slave cylinder push rod tip.
Grease push rod tip. To install, reverse removal procedure.
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1996 Audi A6 Quattro
CLUTCH - AWD 1995-96 Clutch
Fig. 3: Exploded View Of Clutch Release Components (Typical)
Courtesy of AUDI OF AMERICA, INC.
CLUTCH SLAVE CYLINDER
Removal & Installation
1. Remove tensioning clamp. Remove slave cylinder lock pin located on top of transaxle. Slide cylinder
back until push rod is clear. Disconnect and plug fluid line.
2. To install, reverse removal procedure. If cylinder is equipped with a plastic supporting ring, apply a light
film of grease to outer face of ring before installing. Lubricate end of slave cylinder plunger. Bleed
system at slave cylinder. See HYDRAULIC CLUTCH BLEEDING .
OVERHAUL
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1996 Audi A6 Quattro
CLUTCH - AWD 1995-96 Clutch
NOTE: Manufacturer recommends replacement of faulty slave cylinder and does not
provide overhaul procedures.
CLUTCH MASTER CYLINDER
Fig. 4: Exploded View Of Master Cylinder (Typical)
Courtesy of AUDI OF AMERICA, INC.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Center Bearing Bracket Bolt 15 (20)
Clutch Master Cylinder Bolt 15 (20)
Clutch Slave Cylinder Bolt 18 (25)
Crossmember Bolt 33 (45)
Drive Shaft-To-Flange Bolt
8-mm 33 (45)
10-mm 59 (80)
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1996 Audi A6 Quattro
CLUTCH - AWD 1995-96 Clutch
Engine-To-Transaxle Bolt
8-mm Bolt 18 (25)
10-mm Bolt 33 (45)
12-mm Bolt 48 (65)
Flywheel (1) 30 (40)
Pressure Plate Bolt 18 (25)
Shift Rod Bolt 15 (20)
Starter Bolt 40 (54)
Torque Arm-To-Body Bolt 33 (45)
Transaxle-To-Subframe Bolt 33 (45)
(1) Plus 1/2 turn (180 degrees).
7:19:45 PM Page 7
