The clutch consists of a pressure plate with a friction surface, a driven disc with friction linings, and a second friction surface, which is the flywheel. The flywheel and pressure plate are directly connected to the engine crankshaft, and the driven disc is mounted on the splines of the gearbox input shaft.
The diaphragm spring mechanism creates a force that combines the work of the flywheel, pressure and driven discs to ensure joint rotation, in this case the clutch is engaged and transmits torque from the engine to the gearbox. The clutch is controlled by the clutch pedal.
The clutch is released as follows. As a result of pressing the clutch pedal, the piston in the master cylinder moves, compressing the fluid, the pressure of which is transmitted through the hose to the clutch slave cylinder, the piston of which in turn acts on the clutch release fork. The release fork moves the release bearing, which presses on the center of the diaphragm spring, thus releasing the engagement force around the perimeter of the spring and moves the pressure plate backwards. This releases the driven disk, after which the motor shaft and gearbox shaft can rotate independently of each other.
Friction linings are riveted on both sides of the driven disk. The leading part of the disc is connected to the hub through the parts of the torsional vibration damper, which provides an elastic connection between them. Vibration damper reduces dynamic loads that cause twisting (unwinding) transmission shafts, which occur when a sharp change in vehicle speed, hitting bumps in the road, abrupt engagement of the clutch, as well as due to uneven engine torque. Elastic vibrations of transmission parts lead to the appearance of noise in mechanisms and units, as well as to vibrations, as a result of which damage to parts is possible if the amplitude of elastic vibrations reaches significant values. An absorber serves to absorb the energy of elastic torsional vibrations.
Clutch adjustment is automatic.
Depending on the design of the flywheel, different clutch discs are used. When a one-piece flywheel is installed on the engine, a clutch disc with vibration damper springs is installed. When installing a two-section (double mass) flywheel with an intermediate elastic element, with a damping system, a clutch disc without vibration damper springs is installed.
Each time the clutch is engaged/disengaged, there is a slight wear on the friction linings of the clutch drive plate. As a result of wear, the drive disc must be replaced after the vehicle has driven 100,000 km. The driving distance depends on the loads on the vehicle during operation and driving style.
![](https://www.audimanual.ru/img/a6/0479.jpg)
Pic. 5.1. Clutch
1 - manual transmission,
2 - support with a spherical tip,
The spherical tip must be lubricated with a molybdenum disulphide lubricant (MoS 2).
Tightening torques:
- to the gearbox housing made of aluminum alloy 25 Nm;
- to the magnesium alloy gearbox housing 20 Nm.
3 - intermediate element,
4 - disc spring,
The convex side of the spring must point towards the guide bush.
5 - round sealing ring,
When installing, a new O-ring must be used.
6 - sealing ring of the input shaft of the gearbox,
Install all the way.
7 - guide sleeve of the clutch release bearing,
8 - spring,
Installed on the clutch release fork,
9 - clutch release fork,
10 - self-locking bolt,
Tightening torques:
- to the aluminum alloy gearbox housing 35 Nm.
- to the magnesium alloy gearbox housing 25 Nm.
11 - clutch release bearing,
The bearing must not be washed in solvent, as otherwise the grease will be washed out of it. Noisy bearing needs to be replaced
12 - bolt, 20Nm,
13 - clutch slave cylinder,
14 - pusher,
Apply copper-based grease to the pusher head.
![](https://www.audimanual.ru/img/a6/0480.jpg)
Pic. 5.2. Flywheel and clutch disc
1 - flywheel,
2 - bolt, 60 Nm + + tighten by 90°
On models with a V6 diesel engine - 60 Nm + turn 180°.
When installing, use new bolts.
3 - clutch drive disc,
Mounting position: The springs must be on the side of the pressure plate.
4 - pressure plate,
5 - bolt, 25 N·m,
6 - needle bearing,
A, B - colored marks (only on models with 2.5 / 2.8-I engines)
When installing the pressure plate, the marks on the flywheel and pressure plate must be aligned.
![](https://www.audimanual.ru/img/a6/0481.jpg)
Pic. 5.3. Hydraulic clutch
1 - replenishment tank of the brake system,
2 - hose,
3 - clutch pipeline,
4 - bracket,
5 - clutch pedal,
6 - bolt, 20 N·m,
7 - finger,
8 - clutch master cylinder,
9 - sealing ring,
10 - safety clip,
11 - gearbox,
12 - clutch slave cylinder,
After removing the clutch slave cylinder, do not depress the clutch pedal. If a plastic support ring is installed in the clutch slave cylinder, lubricate the end surface of the ring before installation. When installing the clutch slave cylinder, push the piston into the cylinder just enough to allow the fixing bolt to be screwed in.
13 - bleed valve, 5 Nm,
When bleeding the hydraulic clutch actuator, be careful not to let brake fluid come into contact with the gearbox.
14 - dust cap,
15 - dust cover,
16 - gearbox bracket,
17 - a bolt with an internal hexagon, 25 Nm,
18 - nut, 2 Nm,
19 - seal
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