Slave cylinder, removing and installing: Installing

WARNING: This page is about a different car, the 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Installation is perform 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 slave cylinder is inserted at an angle, there is a danger that the operating rod will be guided past the clutch release lever.
When installing, press in slave cylinder so that securing bolt can be installed easily.
Always replace securing bolt.

Fig 1: Identifying Slave Cylinder Hose/Line Assembly

GW00005265

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 2: Coat Boot Area Of Clutch Slave Cylinder With Lithium Grease

GW00005262

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 3: Clutch Slave Cylinder, Bracket And Hose/Line Assembly

GW00005263

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 4: Guiding Slave Cylinder Into Bore Of Transmission Housing

GW00005264

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 hex 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 5: Slave Cylinder Bracket And Fastener

GW00005261

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Fig 6: Selector Shaft Lever Nut

GW00017871

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install selector shaft lever and tighten nut - arrow -.
Bolt drive axle (left-side) to flange shaft → 40 - FRONT SUSPENSION

Vehicles with 6-cylinder engine:

Screw heat shield for drive axle (left-side) onto transmission.
Install exhaust system and perform stress-free alignment → 3.0 Liter 6-Cyl. 5V Engine Mechanical, Engine Code(s): AVK - 26 EXHAUST SYSTEM, EMISSION CONTROLS .

Tightening torques

Component	Nm
Slave cylinder to transmission* See note	23
Selector shaft lever to transmission	23
Heat shield for drive axle to transmission	23

* replace bolt