Audi Workshop Service and Repair Manuals

Removing and installing clutch slave cylinder Special tools and workshop equipment required

t  Hose clamps, up to 25 mm -3094- Removing   Note t  If you suspect a defective clutch slave cylinder, perform function test prior to renewing → Chapter „Notes on removing and installing clutch master cylinder and slave cylinder“. t  If the slave cylinder is removed from gearbox with the pipe/hose assembly still attached, make sure you do not press the clutch pedal. Otherwise, the piston will be pressed out of the slave cylinder and be destroyed. –  Remove air cleaner housing completely → Rep. gr.24.   Caution Follow steps required when disconnecting battery → Electrical system; Rep. gr.27.

–  With ignition switched off, disconnect battery earth strap -arrow-. –  Remove battery → Electrical system; Rep. gr.27.

–  Remove battery tray -arrows-.

Vehicles with metal gate relay lever -B-: –  Detach securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-. –  Detach securing clip -arrow 2- for gate selector cable from gate relay lever -B-. –  Pull both cables off pins.   Note Arrows -3 … 4- can be disregarded.

Vehicles with plastic gate relay lever with detent -arrow 2- –  Detach securing clip -arrow 1- and pull gear selector cable off gearbox selector lever -A-. –  Detach gate selector cable from cable end-piece → Anchor. –  Press detent -arrow 2- down onto stop and remove gate relay lever together with cable end-piece. Move gate relay lever in normal direction of operation.   Note -Arrow 3- can be disregarded.

Vehicles with plastic gate relay lever with clip -arrow 1- –  Pull out clip -arrow 1- and remove gate relay lever together with cable end-piece -arrow 2-.

Continued for all vehicles: –  Detach cable support bracket from gearbox -arrows-. –  Tie back gear selector cable and gate selector cable.

–  Then detach gearbox support -arrows A-. –  Remove clutch slave cylinder -arrows B-.   Note

Make sure that no brake fluid escapes onto the gearbox. If this does happen, clean the affected area thoroughly. –  Place a lint-free cloth under the clutch slave cylinder. –  Using hose clamp -3094-, clamp off pipe/hose assembly going to clutch master cylinder. –  Pull out clip -1- as far as it will go, move pipe/hose assembly -2- clear at bracket and disconnect from clutch slave cylinder.   Caution Do not operate clutch pedal after disconnecting pipe/hose assembly.

Installing Installation is carried out in reverse sequence; note the following: –  Connect pipe/hose assembly to clutch slave cylinder → Fig.. –  Lubricate end of plunger with grease for clutch plate splines -G 000 100-. –  Install clutch slave cylinder and tighten bolts -1- and -2-. Tightening torque → Item –  Clip pipe/hose assembly into bracket -arrow-. –  Remove hose clamp -3094-.

–  Fit gearbox support and tighten bolts -arrows-. Tightening torques → Item –  Bleed clutch system → Chapter.   Note

To install, lubricate bearings and moving surfaces with grease -G 000 450 02-. Metal gate relay lever -B-: –  Attach gear selector cable to gearbox selector lever -A- and secure with securing clip -arrow 1-. –  Attach gate selector cable to gate relay lever -B- and secure with securing clip -arrow 2-.   Note Arrows -3 … 4- can be disregarded.

Plastic gate relay lever with detent -arrow 1-: –  Insert gate relay lever with cable end-piece as far as stop. l  Gate relay lever is secured by detent -arrow 1-. l  Cable end-piece is secured by detent -arrow 2-. l  Ensure that components engage securely.

Plastic gate relay lever with clip -arrow 1- –  Fit gate relay lever and secure with clip -arrow 1-. Continued for all vehicles: –  Adjust selector mechanism → Chapter. –  Install battery tray and battery → Electrical system; Rep. gr.27. –  Install complete air cleaner housing → Rep. gr.24.