Audi Workshop Service and Repair Manuals

Removing and installing clutch slave cylinder on vehicles with 8-cylinder engine Special tools and workshop equipment required

t  Engine and gearbox jack -V.A.G 1383 A- 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.

–  If fitted, loosen quick-release fasteners -2- and -3- and remove rear noise insulation -B-. –  Loosen bolts/quick-release fasteners -1- and -2- and remove front noise insulation -A-.

–  Disconnect exhaust system at clamps -arrows-.   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.

–  Apply lifting column of engine and gearbox jack -V.A.G 1383 A- to rear cross member from below (place a block of wood -arrow- between lifting column and cross member). –  Support rear cross member with engine and gearbox jack -V.A.G 1383 A-. –  First unscrew bolts -1- and -2-, then bolts -3- and -4-.

–  Lower rear cross member slowly with engine and gearbox jack -V.A.G 1383 A- until distance between rear cross member and body reaches dimension -x-. l  Dimension -x- = 60 mm

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

–  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 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  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  To facilitate assembly, engage 6th gear before fitting slave cylinder. 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.

–  If fitted, engage bracket for hose/pipe assembly -3- at 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. –  Attach drive shaft to flange shaft → Rep. Gr.40. –  Bolt heat shield for drive shaft onto gearbox. –  Install tunnel cross member → Chapter. –  Install exhaust system and perform stress-free alignment → Rep. Gr.26. Tightening torques

Component	Nm
Heat shield for drive shaft to gearbox	23