Note: Please refer to the warnings at the beginning paragraph 2 about the dangers of hydraulic fluid.
Withdrawal
1. The slave cylinder is mounted on top of the gearbox bell. Although it can be accessed from under the hood, it can be improved slightly by lifting the front of the car to get to the bottom of the cylinder.
2. Apply the handbrake, raise the front of the vehicle and install the jack stands.
3. Clamp the hydraulic line rubber with a suitable clamp to prevent fluid loss.
4. Turn away a connecting nut and disconnect a tube from the cylinder. Plug the tube and cylinder inlet to keep dirt out of the system.
5. Turn away a bolt of fastening and remove the working cylinder. When removing the cylinder, remove the hose bracket.
Repair
6. Audi do not make repair kits, but other factories do.
7. Clean exterior surfaces before starting repair.
8. Remove the rubber boot and remove the stem.
9. Take out a lock ring from an entrance to the cylinder, remove the piston and a spring.
10. Clean the components and make sure they are intact. If the piston and cylinder show excessive wear or corrosion is evident, the entire cylinder is replaced. If the piston and cylinder are in good condition. Remove all rubber seals from them and replace with new ones.
11. Immerse new seals in hydraulic fluid and install them on the piston using no tools other than fingers. The sealing lips must face the spring.
12. Insert the spring into the cylinder, immerse the piston in hydraulic fluid and carefully insert the piston.
13. While pressing the piston with a screwdriver, install a new circlip 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 is the reverse of the procedure. Apply some lithium grease to the outer surface of the rubber boot before installing it into the hole in the gearbox (pic. 5.15).
Tighten the mounting bolt to the specified torque and bleed the system as described in paragraph 2. Stem tip in contact with "fork" should be lightly lubricated with molybdenum grease. Make sure the stem aligns with the notch on the 'fork'. The cylinder must be inserted into the gearbox housing before the mounting bolt is installed. A special guide bolt can be purchased from your dealer to simplify installation. Due to the limited access and considering that the cylinder must be inserted against considerable resistance from the internal return spring, installation must be done in stages. Fully insert the cylinder first (without hose bracket), aligning the mounting bolt holes. Then install the mounting bracket, tubes so that the front tabs are aligned with the cutouts on the cylinder. While holding the cylinder in this position, insert the mounting bolt and tighten it to the specified torque. Install the handset on the bracket.
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