FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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6 SPD. M/T 02X AWD



Slave cylinder, removing - 6 Spd. Manual Transmission 02X All Wheel Drive

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

Special tools, testers and auxiliary items required





^ Torque wrench V.A.G 1331
^ Lithium grease G052150A2
^ Copper grease Z381351TE





Removing

- On vehicles equipped with auxiliary heater, remove bolts - arrows - securing exhaust pipe of auxiliary heater to sound insulation.





- Loosen bolts/quick release fasteners - 1 - and - 2 - and remove front sound insulation - A -.
- If installed, loosen quick release fasteners - 3 - and remove rear sound insulation - B -.





Vehicles with 6-cylinder engine:

- Disconnect exhaust system at clamp (left-side) - left arrow -.

Note:
^ The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10 degrees - otherwise it can be damaged.

- Remove front exhaust pipe (left-side) with catalytic converter.





- Remove heat shield - arrows - for drive axle (left-side).

Continued for all vehicles:

- Remove drive axle (left-side) - 1 - from flange shaft and move to front, making sure you do not damage surface protection.





- Remove nut - arrow - and detach selector shaft lever from selector shaft.





- Remove bolt - arrow - and take out slave cylinder from rear.

Note:
^ Do not depress clutch pedal after removing slave cylinder. The slave cylinder would then be destroyed once pedal force exceeds approx. 300 N.





- To remove hose/line assembly, use a screwdriver to pry off clip - A - as far as stop. Only then can the hose/line assembly be pulled out.

Installing

Installation is in reverse sequence or removal. Note the following:

Note:
^ Do not allow brake fluid to come into contact with the transmission. If necessary, clean the transmission housing.
^ If the slave cylinder is inserted at an angle, there is a danger that the operating rod will be guided past the clutch release lever.
^ When installing, press in slave cylinder so that securing bolt can be installed easily.
^ Always replace securing bolt.





- To connect line to slave cylinder, press in retaining clip - A - as far as it will go.
- Push line - B - into 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.





- Attach bracket for hose/line assembly - 3 - to 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 hex 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 -.
^ 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 push 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 approx. 300 N.





- Tighten bolt - arrow - to specified torque.
- If line-hose assembly was disconnected at slave cylinder, the clutch system has to be bled after installing slave cylinder.





- Install selector shaft lever and tighten nut - arrow -.
- Bolt drive axle (left-side) to flange shaft.

Vehicles with 6-cylinder engine:

- Screw heat shield for drive axle (left-side) onto transmission.
- Install exhaust system and perform stress-free alignment.

Tightening torques