Subpage of MembersPage/MarcellGal/PowerAndTraction
On Audi 80,90,100,200,5000, etc... the clutch pedal pushes the clutch cylinder via a thin 6mm rod. This rod suffers small internal fructures, wears and breaks after 15..18 years even with the factory clutch. With a strengthened clutch this will break very fast.
The bent and broken rod from my audi:
- You want to keep at least a spare strengthened (8mm should be fine) clutch-pedal to cylinder rod
- so when the rod breaks on your holiday, and you're 1000km away from your workshop with the 1500kg unmovable piece of metal, you can fix it with the help of a local repair shop in 3 hours instead of 3 days.
- If possible, replace it at home
On 2007-05-18 (Friday afternoon), in Budapest (a city with not too many audi-s), one workshop was calling the other:
- hi, we're stuck a bit here, struggling with a broken clutch-rod in an audi80
- hi, we're doing the same here (yes, they were fighting the same problem at the other location, at the very same moment. You can read about it on internet if you don't believe this happens often. Or you should see the factory rod and you'll laugh or cry)
- hint: some compressed air from here and there helped to move parts which were otherwise seemed stuck
Clutch pedal switch
- when pressed with TPS < 50% , activates launch
- when pressed with TPS > 50% , activates shiftcut
A series switch will be applied (so it can be disabled), but not absolutely necessary.
Using brake-switch - snippets from irc, Emil and Teppo
- in 80q and ur quattro they have provision for the same switch as brake switch
- emil: exactly the same provision on both pedals. The brake switch fits in the same hole
- I guess it activates (goes ON) very early (when touching the pedal)
- emil_ it was adjustable
- emil_ there was some rubber and a clip also
- kalske it needs couple of small parts to be fitted (one 431721283B and installation will be very easy)
kalske original brake light switch 443945515 kalske 10+ eur, pic:
I got an audi brakelight switch, similar to the one on the pic: measures 0.4 Ohm normally; infinite Ohm when pushed, even just 0.3mm. Obviously they made it more robust by disconnecting the circuit as pushed. Just perfect for the input activation: the pedal normally keeps it pressed (infinite Ohm), and releases it when the pedal is pushed.
- hella 6DD 008 622-161
- kalske same part in all audis of that age
- Goes to the pedal near the pedal shaft ? With so short button-travel that must be the case
- emil_ it just fits, and are adjustable, on one of the cars we got it correct first try. We had to move it on the sport quattro
- emil_ the sport quattro guy pushed his stock aan engine to 340 kpa last weekend by mistake, still nothing broken! gt40R turbo
"Just fits" ... finally installed the breaklight switch to the clutch. Although there was provision, it took a few hours total. Every time I tested it was OK, and when I tightened the M12x1.5 female it went bad. When after 3 failures it finally worked, than I installed a series switch so it can be disabled.
note: a washer would have helped a lot, the hole was too big and the female (when tightened to final) twisted the whole switch a bit that changed the position
I still have to connect to ECU, take up carpet, configure (same input for launch and shiftcut can be configured since 1.1.31 and function (at the time of input activation) is selected by TPS: TPS<iac_tpsthreshold => launch. Otherwise shiftcut.
- Emil said: there was some rubber/plastic distance there too.
- Not sure what exactly he's thinking about. There was a trashgrade rubber at the tip of the brakelight button. Almost as if it wants to fall out any minute (but it hopefully stays).
Cruise switch is both electric and pneumatic - different than brakelight switch, but same mounting provision
kalske cruisecontrol is done with a vacuum pump and diaphragm wich puls the throttle
kalske that vacuum line is routed to the pedal swicthes as well : [cruisecontrol set on ebay]