6-speed manual gearbox 0A3, four-wheel drive — Servicing clutch release mechanism — AUDI

🧭 Before you start

Fits: Audi A6 C6 (4F, 2004–2011)

• Renewed: o-ring in gearbox housing

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• Before installing clutch release lever, apply a thin coat of copper grease (commercially available) to contact surface for plunger of clutch slave cylinder.
• Before installing the gearbox, glue the loose plastic ring back onto the bearing with adhesiveAMV 195 KD1 01.
• Lubricate new O-ring with gear oil before installing.
• Press in oil seal for input shaft “Installation depth - oil seal for input shaft”. Make sure oil seal remains straight.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Slacken off bolt (1) and remove leaf spring (2).
2. Remove clutch release lever (3) together with release bearing.
3. Disengage retaining tabs of release bearing at release lever.
4. Before installing clutch release lever, apply a thin coat of copper grease (commercially available) to contact surface for plunger of clutch slave cylinder.
5. Fit clutch release lever (3) with release bearing onto guide sleeve.

6. Insert leaf spring (2).
7. Clean thread of bolt (1) with a wire brush. Then insert bolt (1) with locking fluidAMV 185 101 A1 and tighten to 24 Nm. — 24 Nm (18 lb-ft)
8. Before installing the gearbox, glue the loose plastic ring back onto the bearing with adhesiveAMV 195 KD1 01.
9. ⚠ Grating/creaking noises can occur when clutch is operated.Lack of grease at the bearings (arrows) on the release bearing assembly can cause creaking/grating noises when the clutch is operated.Grease bearings (arrows) on release bearing assembly thoroughly with lubricating pasteG 000 150. A thin coating of grease is not sufficient.Remove grease in bearing surface for guide sleeve: bearing of release bearing on guide sleeve must be free of grease. — Unscrew bolts (arrows) and remove retaining piece (1).
10. Fit a thin insulating hose or shrink hose tightly over splines of input shaft.
11. Pull guide sleeve (2) out of gearbox housing.
12. Renew O-ring in gearbox housing .
13. Pack space between sealing lip and dust lip with sealing greaseG 052 128 A1.
14. Coat outer circumference of guide sleeve with gear oil.
15. Push guide sleeve (2) over input shaft and into gearbox housing.
16. Remove insulating hose/shrink hose.
17. Fit retaining piece (1).
18. Clean threads of bolts (arrows) with a wire brush. Then insert bolts with locking fluidAMV 185 101 A1 and tighten to 24 Nm. — 24 Nm (18 lb-ft)
19. Pry out O-ring (arrow) using a small screwdriver.
20. Lubricate new O-ring with gear oil before installing.
21. Lightly lubricate outer circumference of oil seal with gear oil.
22. Press in oil seal for input shaft “Installation depth - oil seal for input shaft”. Make sure oil seal remains straight.
23. Pack space between sealing lip and dust lip half-full with sealing greaseG 052 128 A1.

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