02XA Transmission

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)

Removing

• Before replacing the clutch slave cylinder, perform a function test first. Refer to => [ Master Cylinder and Slave Cylinder General Information ] Description and Operation.

• 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 pipe and catalytic converter.

- 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 ] 02XA Transmission.

• 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 -.

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 plunger of the clutch slave cylinder was probably guided past the clutch release lever. Beyond a pedal force of approximately 300 N, clutch slave cylinder is destroyed.

- If hose/line assembly was disconnect at clutch slave cylinder, clutch system must be bled after installing clutch slave cylinder. Refer to => [ Clutch System, Bleeding ] 02XA Transmission.

- Install the selector shaft lever and tighten the nut - arrow -. Tightening specification => [ (Item 24) Cap nut, 20 Nm ] Selector Mechanism Assembly Overview.





- Attach the left drive axle to the flange shaft.

Vehicles with 6-cylinder engine:

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

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

Tightening Specifications