Note: Refer to warnings at the beginning paragraph 2 about the harmfulness of hydraulic fluid.
Removal
1. The slave cylinder is mounted on top of the transmission bell housing. Although it can be accessed from under the hood, it can be improved slightly by raising the front of the car to access the cylinder from below.
2. Apply the handbrake, raise the front of the vehicle and install safety supports.
3. Clamp the rubber part of the hydraulic line with a suitable clamp to prevent fluid loss.
4. Unscrew the union nut and disconnect the tube from the cylinder. Plug the tube and the cylinder inlet to prevent dirt from getting into the system.
5. Loosen the mounting bolt and remove the slave cylinder. When removing the cylinder, remove the hose mounting bracket.
Repair
6. Audi does not produce repair kits, but other factories do.
7. Before starting repairs, clean the outer surfaces.
8. Remove the rubber boot and remove the rod.
9. Remove the retaining ring from the cylinder inlet, remove the piston and spring.
10. Clean the components and check for damage. If the piston and cylinder are excessively worn or corrosion is evident, replace the entire cylinder. If the piston and cylinder are in good condition, remove all rubber seals and replace them with new ones.
11. Soak the new seals in hydraulic fluid and install them on the piston using only your fingers. The sealing edges should face the spring.
12. Insert the spring into the cylinder, immerse the piston in hydraulic fluid and carefully insert the piston.
13. Using a screwdriver to push the piston down, install the new snap ring into the cylinder, making sure that the legs of the ring are held by the cylinder.
14. Insert the rod into the piston and install the rubber boot.
Installation
15. Installation - reverse procedure. Apply a small amount of lithium grease to the outer surface of the rubber boot before installing it into the hole in the gearbox (Fig. 5.15).
Tighten the mounting bolt to the specified torque and bleed the system as described in paragraph 2. The end of the piston rod that contacts the fork should be lightly lubricated with molybdenum grease. Make sure that the piston rod is aligned with the recess on the fork. The cylinder should be inserted into the gearbox housing before installing the mounting bolt. To simplify installation, you can purchase a special guide bolt from your dealer. Due to limited access and considering that the cylinder must be inserted against significant resistance from the return internal spring, installation should be done in stages. First, fully insert the cylinder (without hose mounting bracket), aligning the holes for the mounting bolt. Then install the mounting bracket, tubes so that the front protrusions are aligned with the cutouts on the cylinder. Holding the cylinder in this position, insert the mounting bolt and tighten it to the specified torque. Install the tube on the bracket.