Slave cylinder fitting with gearbox in place

[andyg plym]

Hi all

Having a complete nightmare trying to re-fit my clutch slave cylinder, getting it out was bad enough but it almost seems impossible to put back in!

Anyone have any suggestions? I have already removed the gearbox mount to get better access but the issue I am having is compressing the cylinder to be able to align up the 13mm bolt.

Appreciate that these are best replaced when the gearbox is out but surely someone has done one in situ?

Cheers

[irishs2]

I got an ATE (even though I orded a sachs) replacement and its impossible to fit without modification of the slave or the gear selector spider .

http://www.s2forum.com/forum/showpost.php?p=840610&postcount=470

[UrS4boy]

Deephouse's (Brian C's) clutch slave cylinder DIY (ported from *other* places)

Having a complete nightmare trying to re-fit my clutch slave cylinder, getting it out was bad enough but it almost seems impossible to put back in! Anyone have any suggestions? I have already removed the gearbox mount to get better access but the issue I am having is compressing the cylinder to be able to align up the 13mm bolt. Appreciate that these are best replaced when the gearbox is out but surely someone has done one in situ?

Deephouse (Brian C) had some trick that he shared on the old Audiworld UrS forum, which I then ported to the quattroworld UrS forum and now I have ported here.

Deephouse's (Brian C's) clutch slave cylinder DIY (ported from *other* places)

http://www.s2forum.com/forum/showthread.php?t=77607

[Error404]

AAN is easier than the ABY unfortunately due to the linkage.
Like Eric says compare the slave housing to the old one as many pattern parts need to be ground down to fit.
Remove the linkage for easier access. As per Daves link, greasing the boot does make life loads easier.

HTH

[chris]

slave

just done mine on my urs4, ball ache, grease the boot, and then insert slave with retaining bolt flange rotated 90 degrees up,clockwise [the bolt face flange is horizontal]insert and rotate anticlockwise , should work , but was a urs4 v8 , i remember getting my local garage to do my rs2 [years ago] they took the box out

[andyg plym]

**** you euro car parts! Had it sat in the bell housing perfectly and put a mirror in the area to see the holes do not line up! I removed the complete linkage and access is loads easier

[UrS4boy]

just done mine on my urs4, ball ache, grease the boot, and then insert slave with retaining bolt flange rotated 90 degrees up,clockwise [the bolt face flange is horizontal]insert and rotate anticlockwise , should work , but was a urs4 v8 , i remember getting my local garage to do my rs2 [years ago] they took the box out

So Chris, do you think that I could have done that lying on the street, car at the curb, presumably jacked up on stands, in the rain?

(This refers to my 94 S4 V8 clutch failure back in Dec. 2013 when I was berated for having taken the car to a shop).

[s2driveruk]

must be one of the few things that is easier on the 3b...i replaced mine with no issues with an oem one...one 13mm bolt and then the hydraulic line. I dont remember any real issues...

[Rikki Kitto]

Had the same nightmare after trying to fit it for ages realised moulding is wrong ended up buying genuine item from Audi

[speeding-g60]

it does suck. i hate it. but putting it in with the flange horizontal, as mentioned, and then rotating down works well. takes just a little push forward to align the holes using a prybar or flat screwdriver behind it.

i have gotten good at it i take the trans out so much. on the floor under the car in the trailer for instance. BTDT many times.

[Rikki Kitto]

The original Audi one went in with no issues

[chris]

slave

So Chris, do you think that I could have done that lying on the street, car at the curb, presumably jacked up on stands, in the rain?

(This refers to my 94 S4 V8 clutch failure back in Dec. 2013 when I was berated for having taken the car to a shop).

yes, if it had not been raining this did take me a good hour or so and numerous attempts, no berating coming from my end on your experience .
oh forgot to mention i did get a eye full of dot 4 for my trouble , spent the next week thinking i was going to be blind, so i did just wish i had pulled the box.

[bertman]

**** you euro car parts! Had it sat in the bell housing perfectly and put a mirror in the area to see the holes do not line up! I removed the complete linkage and access is loads easier

Same thing happened with me Andy.Ordered one from ecp,what a pile of aftermarket cr'p that was.Took me a long time like you to realise that the bolt hole was 5mm out.Drilled out the hole to a larger diameter and it fitted.Just looked and that was a pagid one.
The sachs one fits perfectly

[andyg plym]

Finally back on the road! We ended up using the Ecp one and ground down the edges and made it fit....lovely clutch pedal now.

I would suggest if you do one to remove the near side gearbox mount and gear linkage , it makes access so much easier

[Chris5044]

Trying to take out the out slave on an aby is impossible. Theres a plate on top of the gearbox, blocking the twisting action of the slave cylinder to come out. Therefore requires the gearbox out.... im aborting now and will approach a garage as i dont have the tools or facilities for this anymore

Unless any of ypu lot know something I dont??

Any help would be in dire need right now....