Clutch slave cylinder on vehicles with 4.2 Liter V8 engine (S4), removing and installing

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2007 Audi S4, 2007 Audi RS 4, and 2006 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Observe the notes on removing and installing clutch master cylinder and slave cylinder → Clutch master cylinder and slave cylinder, notes on removing and installing .

Special tools, testers and auxiliary items required

Fig 1: Identifying Engine/Transmission Jack V.A.G. 1383 A

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Engine/transmission jack V.A.G 1383 A

Fig 2: Removing Quick-Release Fasteners, Screws And Noise Insulation

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Removing

Release quick release fasteners - 1 - , unscrew bolts - 2 - and remove noise insulation.

Fig 3: Locating Clamping Sleeves

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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.

Fig 4: Supporting Tunnel Cross Member Using VAG1383A Engine/Transmission Lift And A Piece Of Wood

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Remove universal mounting V.A.G 1359/2 from engine and transmission jack V.A.G 1383 A and place a wooden block - arrow - on the lifting column in its place.
Support the rear cross member with engine and transmission jack V.A.G 1383 A.
First unscrew bolts - 1 - and - 2 - , then bolts - 3 - and - 4 -.

Fig 5: Identifying Distance Between Cross Member And Body Reaches Dimension

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Lower rear cross member slowly with engine and transmission jack V.A.G 1383 A until distance between rear cross member and body reaches dimension - x -.

Dimension - x - = 60 mm

Fig 6: Axle Shaft Shielding Plate

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

Fig 7: Slave Cylinder Bracket And Fastener

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Remove bolt - arrow - and take out clutch slave cylinder from the rear.

NOTE:

Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.

Fig 8: Removing Hydraulic Line From Slave Cylinder

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To remove hose/line assembly, use a screwdriver to Pry off clip - A - as far as the stop. Only then can the hose/line assembly be pulled out.

Installing

Installation is performed in reverse sequence; note the following:

NOTE:

Do not allow brake fluid to come into contact with the transmission. If necessary, clean the transmission housing.
If the clutch slave cylinder is inserted at an angle, there is a danger that the operating rod will be guided past the clutch release lever.
To facilitate assembly, engage 6th gear before fitting slave cylinder.
When installing, press in slave cylinder so that securing bolt can be installed easily.

Always replace securing bolt.

Fig 9: Identifying Slave Cylinder Hose/Line Assembly

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

Fig 10: Coat Boot Area Of Clutch Slave Cylinder With Lithium Grease

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Before inserting slave cylinder in transmission housing, lubricate area - a - of sleeve with lithium grease G052150A2 .
Lightly lubricate surface where operating rod and clutch release lever make contact with copper grease Z381351TE .

Fig 11: Clutch Slave Cylinder, Bracket And Hose/Line Assembly

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Engage bracket for hose/line assembly - 3 - at slave cylinder - 4 -.

Fig 12: Guiding Slave Cylinder Into Bore Of Transmission Housing

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Guide slave cylinder - 1 - into opening in transmission housing keeping it as straight as possible (without tilting operating rod - arrow A -) and insert in recess - arrow B - on clutch release lever - 3 -.
Use new hexagon socket head bolt - 2 - to secure to transmission.

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 -.

Fig 13: Slave Cylinder Bracket And Fastener

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Tighten bolt - arrow - to specified torque.
If the line-hose assembly was disconnected at the slave cylinder, the clutch system has to be bled after installing slave cylinder → Hydraulic clutch system, bleeding .

CAUTION: After installing the slave cylinder carefully press the clutch pedal. If you feel an unusually strong point of resistance when depressing the clutch pedal, you must not press it down further. The operating rod 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.

Bolt drive shaft to flange shaft → 40 - FRONT SUSPENSION
Bolt heat shield for drive shaft onto transmission.
Install tunnel cross member → 40 - FRONT SUSPENSION

Install exhaust system so it is free of stress → 26 - EXHAUST SYSTEM, EMISSION CONTROLS .

Tightening torques

Component	Nm
Clutch slave cylinder to transmission	23 * See note
Heat shield for drive shaft to transmission	23

* Replace bolt