[01X] 6-SPD FWD
Clutch Slave Cylinder
Special tools, testers and auxiliary items required
- Hose Clamps Up to 25 mm Dia. (3094)
- Lithium Grease (G 052 150 A2)
- Commercially Available Copper Grease
Removing
- Refer to Clutch Master and Slave Cylinder, Testing Function.
- Brake fluid must not come into contact with transmission. If necessary, clean transmission housing.
CAUTION! If the clutch 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 clutch slave cylinder and will get damaged.
Vehicles with V6 gasoline engine:
- Remove rear engine cover - arrows -.
- Remove left cover - 1 - in engine compartment.
- Remove coolant reservoir - arrow -.
- Disconnect the wire to the engine coolant level warning switch (F66) on the bottom of the coolant reservoir and move the reservoir with the hoses still connected - 1 through 3 - to the side.
- Remove the left connector heat shield from the bulkhead, if applicable.
- Remove electrical harness connectors - 1 through 4 - from bracket at left of bulkhead.
- Disconnect electrical connectors - 1 - and - 4 -.
- Free up oxygen sensor wiring.
- Remove the connector bracket.
- Remove nut - 2 - which is accessible from top for left exhaust pipe/exhaust manifold.
- For the sake of illustration, shown with engine removed.
- The nuts - 1 - and - 3 - underneath will be removed later.
All Vehicles
- Remove left front wheel.
- Loosen the fasteners - 1 through 3 - and remove the front - A - and rear - B - noise insulation.
Vehicles with V6 gasoline engine:
- Remove the bolts - 1 through 4 - and then remove the front crossbrace, if applicable.
- Do not bend the flex joint in the front exhaust pipe more than 10�, otherwise it will be damaged.
- Disconnect the exhaust system at the left clamping sleeve - left arrow -.
- Remove the nuts - 1 - and - 3 - underneath on the left front exhaust pipe/exhaust manifold.
- Remove the left front exhaust pipe from the exhaust manifold and remove the front section of the exhaust system.
All Vehicles
- If necessary, remove the left drive axle from the flange shaft and move it forward while being careful not to damage the protective
coating.
- Remove nut - arrow - and remove transmission shift lever from selector shaft.
- Remove the bolt - arrow -, and pull out the clutch slave cylinder toward the rear.
- Do not press clutch pedal after clutch slave cylinder has been removed.
- Clamp the pipe/hose line with a (3094).
- Release the retaining clip - A - with a screwdriver and pull it all the way out.
- Remove the pipe/hose line from the clutch slave cylinder.
Installing
- Install in reverse sequence; note the following points: Replace the bolt.
- Preload the clutch 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 clutch slave cylinder into the transmission housing.
- Lightly coat the contact surface of the clutch release lever plunger with a commercially available copper grease.
- Install the pipe/hose line bracket - 3 - on the clutch slave cylinder - 4 -.
- Guide the clutch slave cylinder - 1 - into the 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 clutch 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 clutch slave cylinder with a new bolt - 2 -.
- Push the securing clip - A - all the way onto the clutch slave cylinder.
- Push the hose/line assembly onto the clutch slave cylinder connection 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 clutch slave cylinder.
If an abnormally difficult pressure point is noticed when depressing the clutch pedal, do not depress the clutch pedal any further.
The clutch slave cylinder plunger was probably guided past the clutch release lever.
Beyond a pedal force of approximately 300 N, clutch slave cylinder is destroyed.
For comparison: the normal pedal force is approximately 115 N.
- Install the transmission selector lever and tighten the nut - arrow -.
- If removed, install the left drive axle on the flange shaft.
Vehicles with 6-cylinder engine
- Install the front exhaust pipe and adjust the exhaust system so that it is free of tension.
- Install the front crossbrace, if applicable.
- Install the left drive axle heat shield.
All Vehicles
- If the pipe/hose line on the clutch slave cylinder was disconnected, the clutch system must be bled after the slave cylinder is installed again.
Tightening Specifications
Clutch slave cylinder to transmission (replace bolt) 23Nm
Transmission shift lever to selector shaft (Replace nut) 20Nm
Heat shield for drive axle to transmission 23Nm