Audi Workshop Service and Repair Manuals

Removing and installing clutch 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 Observe notes → Chapter „Notes on removing and installing clutch master cylinder and slave cylinder“.   Note t  If slave cylinder is removed from gearbox with hose/pipe 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.

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

Vehicles with V6 TDI engine: –  Unbolt heat shield for left-side drive shaft -arrows-.

–  Remove nuts -arrows-.

–  Remove bolt -1-.

–  If fitted, remove tunnel brace -1--arrows-. –  Release clamp -2- and remove front exhaust pipe with catalytic converter -3-.   Note The flexible joint (de-coupling element) on the front exhaust pipe must not be bent more than 10° – otherwise it can be damaged.

Continued for all vehicles: –  Unscrew bolt -arrow- and pull off clutch slave cylinder to 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 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 operating rod 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 operating rod -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 operating rod -arrow A- will be guided past the clutch release lever -3-. –  Secure slave cylinder with new bolt -2-.

–  Press retaining clip -A- in clutch slave cylinder onto limit 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 operating rod 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 V6 TDI engine: –  Install front exhaust pipe and perform stress-free alignment → Rep. Gr.26. –  If fitted, install tunnel brace → General body repairs, exterior; Rep. Gr.66. –  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.