Audi Workshop Service and Repair Manuals

Removing and installing slave cylinder Special tools and workshop equipment required

t  Hose clamps, up to Ø 25 mm -3094- t  Lithium grease -G 052 150 A2- t  Copper grease -Z 381 351 TE- Removing slave cylinder Observe notes → Chapter „Notes on removing and installing master cylinder and slave cylinder“.   Note t  If the slave cylinder is removed from the gearbox with the hose/pipe 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. t  Do not allow brake fluid to come into contact with the gearbox. If necessary, clean the gearbox housing.

–  If fitted, loosen fasteners -2- and -3- and remove rear noise insulation -B-.

Vehicles with 6-cylinder engine: –  Disconnect exhaust system at clamp (left-side) -left arrow-.   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. –  Remove heat shield for drive shaft (left-side). –  Remove front exhaust pipe (left-side) with catalytic converter → Rep. Gr.26.

Continued for all vehicles: –  Unscrew bolt -arrow- and pull off clutch slave cylinder towards rear.   Note Do not depress clutch pedal after removing slave cylinder.

–  Using hose clamp -3094-, clamp off pipe/hose assembly. –  Release retaining clip -A- using a screwdriver and pull out to limit stop. –  Detach pipe/hose assembly from clutch slave cylinder. Installing slave cylinder Installation is carried out in reverse sequence; note the following:   Note t  Renew securing bolt. t  When installing, press in slave cylinder so that securing bolt can be fitted easily.

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

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

–  Guide slave cylinder -1- into opening in gearbox housing, keeping it as straight as possible (without tilting plunger -arrow A-), and insert in recess -arrow B- on clutch release lever -3-.   Note If the slave cylinder -1- is inserted at an angle, there is a danger that the plunger -arrow A- will be guided past the clutch release lever -3-. –  Secure slave cylinder with new bolt -2-.

–  Press in retaining clip -A- on clutch slave cylinder as far as stop. –  Push pipe/hose assembly -B- onto connection on clutch slave cylinder so that retaining clip snaps into place. –  Check secure seating of pipe/hose assembly.   Caution t  After installing the slave cylinder press the clutch pedal carefully. t  If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. t  The plunger of the slave cylinder is likely to have been guided past the clutch release lever. t  The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N. t  For comparison: normal pedal force is approx. 115 N. Vehicles with 6-cylinder engine: –  Install front exhaust pipe and perform stress-free alignment → Rep. Gr.26. –  Install heat shield for drive shaft (left-side). Continued for all vehicles: –  If the pipe-hose assembly was disconnected at the slave cylinder, the clutch system has to be bled after installing slave cylinder → Chapter. Tightening torques

Component	Nm
Slave cylinder to gearbox	23 1)
Heat shield for drive shaft to gearbox	23
l  1) Renew bolt.