[02X] 6-SPD AWD

Clutch Slave Cylinder

Special tools, testers and auxiliary items required
- Torque Wrench (V.A.G 1331)
- Lithium grease (G 052 150 A2)
- Copper grease (Z 381 351 TE)

Removning

- Before replacing the clutch slave cylinder, perform a function test first. Refer to [Master Cylinder and Slave Cylinder General
Information].

- If the clutch slave cylinder is removed from the transmission with hose/line assembly connector, do not operate (depress) clutch
pedal any more. Otherwise, the pistons are pushed out of the clutch slave cylinder and thus damaged.

- Brake fluid must not come into contact with transmission. If necessary, clean transmission housing.



- Loosen the quick-release screws - 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 the left front exhaust.
-



- Remove left drive axle heat shield - arrows -.

All Vehicles

- Remove the left drive axle - 1 - from the flange shaft and move it toward the front being careful not to damage the protective
coating.



- Remove nut - arrow - and remove the selector shaft lever from the selector shaft.



- Remove bolt - arrow -, pull out clutch slave cylinder toward rear.

CAUTION! Do not press clutch pedal after clutch slave cylinder has been removed. Beyond a pedal force of approximately 300 N, clutch slave cylinder is destroyed.



- To remove hose/line assembly, pry out clip - A - to stop using a screwdriver. Only then can hose/line assembly be pulled out.

Installing
Install in reverse sequence; note the following points:

Always replace bolt.

Preload clutch slave cylinder sufficiently so that the bolt can be easily inserted.




- Before installing clutch slave cylinder in transmission housing, boot area - a - must be coated with Lithium Grease (G 052 150 A2).

- Lightly coat contact surface for plunger on clutch release lever with Copper Grease (Z 381 351 TE).

- To connect line to clutch slave cylinder, securing clamps - A - must be pressed down to stop.

- Insert line - B - in clutch slave cylinder until you hear it engage.

- Pull on the pipe/hose line and make sure it is secure.




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




- - Guide clutch slave cylinder - 1 - into transmission housing mounting hole without great sideways movement from working direction of plunger - arrow A -.

- While doing this, insert into recess - arrow B - of clutch release lever - 3 -.

- Tighten the clutch slave cylinder - 1 - with a new bolt - 2 -. Tightening specification � [ (Item 13) Internal hex bolt, 23 Nm ].
If the sl.

- Install the selector shaft lever and tighten the nut - arrow -. Tightening specification � [ (Item 24) Cap nut, 20 Nm ].
Attach the left drive axle to the flange shaft. Refer to � Suspension, Wheels and Steering 40 Removal and Installation.

Vehicles with 6-cylinder engine:

- Attach the left drive axle heat shield to the tranmission.

- Reconnect exhaust system and ensure it is not under stress.

Tightening Specifications

Heat shield for drive axle to transmission 23Nm