Clutch Slave Cylinder on Vehicles With 4.2 Liter V8 Engine (S4), Removing and Installing

Clutch slave cylinder on vehicles with 4.2 Liter V8 engine (S4), removing and installing, 0A3, 6 Spd. M/T AWD

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

Special tools, testers and auxiliary items required

Engine/transmission jack V.A.G 1383 A:

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





- 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.





- 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 -.





- 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





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





- 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 approximately 300 N.





- 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.





- 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.





- 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.





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





- 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 -.





- 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.

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 approximately 300 N.

- Bolt drive shaft to flange shaft.
- Bolt heat shield for drive shaft onto transmission.
- Install tunnel cross member.
- Install exhaust system so it is free of stress.

Tightening torques: