FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Porsche >> 2004 >> 911 Turbo AWD (996) F6-3.6L Turbo >> Repair and Diagnosis >> Transmission and Drivetrain >> Clutch >> Clutch Hydraulic System >> Clutch Slave Cylinder >> Service and Repair

Clutch Slave Cylinder: Service and Repair




Removing and Installing Clutch Slave Cylinder





Component view


Removal

1. Raise vehicle on lifting platform. Disconnect battery.

2. Actuate the clutch pedal at least 25 times with the engine switched off so that the system is depressurised.





3. Undo the screws -arrows- and remove the front cross member.

4. Remove clips from the coolant lines.

5. Remove bracket for the coolant lines.

6. Remove the ventilation connection piece from the clutch housing (3 screws).

NOTE: This makes the area from the pressure line to the clutch slave cylinder more accessible.

7. Push the protection on to the left drive shaft and release the drive shaft at the transmission flange.

NOTE:
- Take care when handling Pentosin. Wear protective glasses, gloves and protective clothing.
- If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY.





8. Remove the pressure reservoir -arrow-. Use an open-ended wrench to undo the pressure reservoir. Then turn the pressure reservoir further (remove) with an oil filter strap.





9. Disconnect (unscrew) the plug connector for the clutch hydraulic system at the body (green lead) -arrow-.





10. Remove the bracket for the slave cylinder (on transmission -arrow- and disconnect the slave cylinder). Only undo the slave cylinder fastening screws (2 screws) -arrows- slightly (do not yet unscrew completely).





11. Disconnect (unscrew) lead -1- on slave cylinder. Pull off return line -2-. To do so, press on the red ring evenly (never on one side) -2a- and pull the lead out evenly while pressing (unlock). To unlock, use a commercially available removal tool. In the process, observe the following note. Unscrew the pressure line -3-. Due to the restricted space, it is sensible to use a commercially available open socket wrench + adapter.

NOTE: The tool for unlocking the return line is the tool already familiar from the 986/996. It was used there for unlocking the steering return line on the servo pump, among other elements.

12. Undo the slave cylinder fastening screws (2 screws). Carefully remove the slave cylinder.





Tightening Torques


Installation

NOTE:
- Before installing the slave cylinder, it is sensible to remove the starter. This guarantees a better test and the unequivocal centring of the tappet push rod of the slave cylinder in the release lever. The slave cylinder can also be held in its installation position from this side.
- Observe the precise position of the slave cylinder before installation. The precise installation position is attained by turning in the vehicle.
- The loosely attached transmission slave cylinder bracket ensures the correct installation height for positioning the slave cylinder screws.

1. Remove the starter.

2. Remove the top cover (rubber cap) on the clutch housing in the area of the release lever.

3. Insert the clutch slave cylinder into the vehicle with the pushrod facing towards the transmission and turn it into its installation position

4. Fasten the transmission-slave cylinder bracket loosely to the slave cylinder with a screw. It is very difficult to attach the screw later.

5. Install the clutch slave cylinder to the transmission housing/release lever. Pay attention to the correct position of the push-rod. Do not tighten the fastening screws yet. This ensures better access to the pressure line.

6. Place pressure line in position.

7. Tighten the pressure line and screw the slave cylinder tight.

8. Insert the return line.

9. Install the hose of the master cylinder line on the slave cylinder.





10. Screw the master cylinder line together -arrow- and insert it into the guide on the body.

11. Install the pressure reservoir.

12. Position the input shaft on the transmission flange and tighten with 81 Nm (60 ftlb.).

13. Install the bracket for the water hoses and clip the hoses into place. Align the hoses.

14. Install the starter.

15. Install the front cross member.

16. Connect the battery and carry out the necessary subsequent work. Refer to Battery, Service and Repair, Power supply (work instructions after connecting the battery).

CAUTION:
Danger of material damage it the wrong fluid is used for the clutch hydraulic system.
Danger of damage to property it too much Pentosin CHF 11 S is filled or it Pentosin comes into contact with the coolant hoses when topping up or filling in.
- Fill Pentosin CHF 11 S only into both supply tanks.
- To prevent overfilling and so overflowing, check the specifications in the clutch, fluid levels description and observe them without fail.
- Multiple steering operations (manoeuvreing) and/or actuating the clutch with the engine switched off change the fluid level in the engine-compartment reservoir. Fluid level rises. In this case, the engine must be run for approx. 20 seconds immediately prior to the fluid level check.
- If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY.
- Replace visibly swollen coolant hoses.

17. Top up hydraulic fluid Pentosin CHF 11 S in the front expansion tank (luggage compartment) and in the engine compartment. Observe the prescribed procedure without fail See Clutch Fluid, Testing and Inspection, Clutch: checking fluid levels.




Pentosin tank in the engine compartment





Front Pentosin tank

18. Bleed the clutch operation (clutch hydraulic system). See Clutch Fluid, Service and Repair, Bleeding clutch operation.

pro multis Credits:Operation CHARM About Operation CHARM