Audi Workshop Service and Repair Manuals

Removing and installing clutch slave cylinder on vehicles with 4-cylinder engine and 6-cylinder TDI engine Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331- t  Lithium grease -G 052 150 A2- t  Copper grease -Z 381 351 TE- Removing   Note t  If you suspect a defective clutch master cylinder, perform function test prior to renewing → Chapter „Notes on removing and installing clutch master cylinder and slave cylinder“. t  If slave cylinder is removed from gearbox with pipe/hose assembly still attached, make sure you do not press clutch pedal. Otherwise, the piston will be pressed out of the slave cylinder and be destroyed. t  Do not allow brake fluid to come into contact with the gearbox. If necessary, clean the gearbox housing.

–  Loosen bolts/quick-release fasteners -2- and -3- and remove rear noise insulation -B-.

–  If fitted, remove noise insulation from wheel housing (left-side) -arrows-.

–  Unbolt drive shaft -1- from flange shaft and move clear to the front. Vehicles with 6-cylinder TDI engine –  Remove heat shield for drive shaft (left-side) -arrows-.

–  Remove nuts -arrows-.

–  Remove bolt -1-.

–  Release clamp -arrow- and remove front exhaust pipe with catalytic converter.   Note The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

Continued for all vehicles –  Remove bolt -arrow- and take out clutch slave cylinder from the rear.   Caution Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.

–  To remove hose/pipe assembly, use a screwdriver to lever off clip -A- as far as the stop. Only then can the hose/pipe assembly be pulled out. Installing clutch slave cylinder Installation is carried out in reverse sequence; note the following:   Note t  Do not allow brake fluid to come into contact with the gearbox. If necessary, clean the gearbox housing. t  For easier installation engage 6th gear before fitting slave cylinder. t  If the clutch slave cylinder is inserted at an angle, there is a danger that the plunger will be guided past the clutch release lever. t  When installing, press in slave cylinder so that securing bolt can be fitted easily. t  Renew securing bolt for slave cylinder.

–  To connect pipe to clutch slave cylinder, press in retaining clip -A- as far as it will go. –  Push pipe -B- into clutch slave cylinder until it engages audibly.

–  Before inserting slave cylinder in gearbox housing, lubricate area -a- of sleeve with lithium grease -G 052 150 A2-. –  Using copper grease -Z 381 351 TE-, lightly lubricate surface where plunger and clutch release lever make contact.

–  Attach bracket for hose/pipe assembly -3- to clutch slave cylinder -4-.

–  Guide slave cylinder -1- into mounting hole in gearbox housing, keeping it as far as possible in line with the operating direction of the plunger -arrow A-. –  At the same time insert in recess -arrow B- on clutch release lever -3-. –  Secure slave cylinder -1- with new bolt -2-. Tightening torque → Item   Note If the slave cylinder is inserted at an angle, there is a danger that the plunger -arrow A- will be guided past the recess -arrow B-.   Caution After installing the slave cylinder press the clutch pedal carefully. If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. The plunger of the slave cylinder is likely to have been guided past the clutch release lever. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. For comparison: normal pedal force is approx. 115 N –  If the pipe-hose assembly was disconnected at the slave cylinder, the clutch system has to be bled after installing slave cylinder → Chapter. –  If necessary, install front exhaust pipe and align exhaust system so it is free of stress → Rep. Gr.26.

–  Attach drive shaft -1- to flange shaft → Rep. Gr.40. –  If fitted, install heat shield for drive shaft (left-side) -arrows-. Tightening torques

Component	Nm
Heat shield for drive shaft to gearbox	23