Genuine Audi 100 Clutch Slave Cylinder

Audi 100 Clutch Slave Cylinder Parts and Q&A

• Slave Cylinder
  4A0-721-261
  Q: How to remove and overhaul the Clutch Slave Cylinder located at the front on Audi 100?

  A:

  The slave cylinder is located on the top of the transmission, and while access is possible from the engine compartment, raising the front of the car for access from below is often preferable. Begin by applying the handbrake, jacking up the front of the vehicle, and supporting it on axle stands. For easier access on the 01E transmission, engage 6th gear on the 6-speed version or 4th gear on the 5-speed version to move the gearchange levers away from the slave cylinder. Clamp off the slave cylinder hydraulic hose with a brake hose clamp, then loosen the hose union on the slave cylinder without fully unscrewing it. Unscrew the mounting bolt and withdraw the slave cylinder, recovering the hose support bracket as it is removed. Unscrew the cylinder from the pipe union and plug the end of the pipe. Although repair kits are not available from Audi, they may be sourced from a motor factor. To overhaul the slave cylinder, clean the exterior surfaces, prise off the rubber boot, and remove the pushrod. Extract the special spring clip from the mouth of the cylinder and withdraw the piston and spring. Clean the components and examine them for wear and deterioration; if excessive wear or corrosion is evident, renew the complete cylinder. If in good condition, remove the seal from the piston and renew it, dipping the new seal in hydraulic fluid before fitting it onto the piston with the seal lip facing the spring end. Insert the spring in the cylinder, dip the piston in hydraulic fluid, and carefully insert it, holding the piston depressed with a screwdriver while pressing a new spring clip into the mouth of the cylinder. Fit the pushrod followed by the rubber boot. Refitting is a reversal of removal, ensuring to tighten the mounting bolt and union to the specified torque while bleeding the system afterward. Lightly lubricate the end of the pushrod that contacts the release lever with molybdenum disulphide grease, ensuring proper engagement with the lever's depression. The slave cylinder must be pressed into the transmission casing before inserting the mounting bolt. For easier refitting, a special mounting bolt with a locating extension can be obtained from Audi, and due to limited access and the internal return spring's force, refitting should be done in stages, first fully inserting the cylinder while ensuring the bolt hole is aligned, then refitting the hose support bracket and tightening the mounting bolt to the specified torque.