[012/01W/0A9] 5 SPD
Slave Cylinder
Special tools, testers and auxiliary items required
- Hose Clamps up to 25 mm Diameter. (3094)
- Lithium Grease (G 052 150 A2)
- Copper Grease (Z 381 351 TE)
Remove slave cylinder.
- If the slave cylinder is removed from transmission with pipe/hose line still connected, do not depress the clutch pedal. Otherwise, the pistons are pushed out of the slave cylinder and thus damaged.
- Brake fluid must not come into contact with transmission. If necessary, clean transmission housing.
- Loosen the fasteners - 2 - and - 3 - and remove the rear noise insulation - B -.
Vehicles with 6-cylinder engine:
- Disconnect the exhaust system at the left clamping sleeve - left arrow -.
- Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.
- Remove left drive axle heat shield.
- Remove left front exhaust pipe and catalytic converter.
All Vehicles
- Remove bolt - arrow - and remove the slave cylinder to the rear.
- Do not press clutch pedal after clutch slave cylinder has been removed.
- Clamp the pipe/hose line with a Hose Clamps up to 25 mm Diameter. (3094).
- Release the retaining clip - A - with a screwdriver and pull it all the way out.
- Remove the pipe/hose line from the slave cylinder.
Install slave cylinder.
- Install in reverse order, paying attention to the following:
- Replace the bolt.
- Preload slave cylinder sufficiently so that the bolt can be easily inserted.
- Coat the area - a - around the boot with Lithium Grease (G 052 150 A2) before installing the slave cylinder into the transmission
housing.
- Lightly coat the contact surface of the clutch return lever plunger with Copper Grease (Z 381 351 TE).
- Install the pipe/hose line bracket - 3 - on the slave cylinder - 4 -.
- Guide clutch slave cylinder - 1 - into transmission housing mounting hole without great sideways movement from working direction of plunger - arrow A - and insert in recess - arrow B - in clutch return lever - 3 -.
- If the slave cylinder - 1 - is guided in angled, there is a risk that the plunger - arrow A - may be guided past the clutch release lever - 3 -.
- Tighten the slave cylinder with a new bolt - 2 -.
- Push the securing clip - A - all the way onto the slave cylinder.
- Push the pipe/hose line - B - onto the slave cylinder until the securing clip audibly engages.
- Pull on the pipe/hose line and make sure is it secure.
CAUTION! Carefully actuate the clutch pedal after installing the slave cylinder.
If an abnormally difficult pressure point is noticed when depressing the clutch pedal, do not depress the clutch pedal any further.
The plunger of the slave cylinder was probably guided past the clutch release lever.
Beyond a pedal force of approximately 300 N, clutch slave cylinder is destroyed.
In comparison: The normal pedal force is approximately 115 N.
Vehicles with 6-cylinder engine:
- Install the front exhaust pipe and adjust the exhaust system so that it is free of tension.
- Install the left drive axle heat shield.
All Vehicles
- If hose/line assembly was disconnect at slave cylinder, then the clutch system must be bled after installing clutch slave cylinder.
Tightening Specifications
Slave cylinder to transmission (replace bolt) 23 Nm
Heat shield for drive axle to transmission 23 Nm