Audi100, '89: Clutch slave cylinder replace or new seals?

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Christoph Bollig - 03 Oct 2006 17:24 GMT

Hi everyone,

On my 1989 Audi 100, the clutch slave cylinder is leaking
occasionally. I had the problem twice now, where I had to check the
brake fluid level regularly for a few days and re-fill from time to
time. At the time, a bit of brake fluid was dripping from the gear
box. After a few days, the leak stopped again. Currently, it's not
leaking.

It seems I have three options:

1) Just flush the whole system (brakes and clutch) with new brake
fluid and otherwise wait and see.

2) Replace the clutch cylinder with a new one (third-party)

3) Buy the seals for $2 and put new seals into the clutch cylinder

I need to flush the brake fluid anyway, since that's probably not been
done for the last 5 to 10 years.

How difficult is it to take the clutch slave out? Is there a procedure
anywhere on the web? I didn't find anything except someone mentioning
that there is a pin which is difficult to get out, but that was on a
Turbo-Quattro.

I would appreciate any recommendations on what best to do in this
case.

Thanks a lot,

Christoph

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Tony - 04 Oct 2006 02:53 GMT

Flushing will not be likely to solve the problem.

Others who have done this have replaced the slave with new. It is enough of a
PITA that if the seal kit doesn't correct the problem you don't want to have to
do the job again.

The pin that was mentioned is a drive pin that, once out, allows the slave to be
pulled out and replaced. The problem is that the slave in on the top of the
bell housing just behind the engine and is awkward to get to but possible. You
will need to have the car up on a lift or on jack stands. Even then it is hard
to reach.

Try searching the history on:
http://forums.audiworld.com/v8/

Don't let the V8 reference worry you. This is the forum for the T44 series '84 -
'91. the posters there are very helpful and have a wealth of knowledge from
hands on experience.

I have rebuilt the clutch master cylinder on thee three times and never a slave
so as long as you are doing the slave it would be a good time to rebuild the
master also. The master is on the floorboard below the clutch pedal. Easy to see
but, again, awkward to reach. You will need to shorten the short end of a metric
Allen to loosen on of the hold-down bolts.

TonyJ
current: a4 1.8TQM APR
previous: four T44s '84 - '91

> Hi everyone,
>
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>
> Christoph

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Christoph Bollig - 04 Oct 2006 09:07 GMT

Hi Tony,

Thanks for your advice. I can see the slave cylinder from the top, I
guess the open space above the clutch is where the turbo sits in the
turbo models. I will look whether I can see the pin when I am at the
car the next time.

Christoph

> Flushing will not be likely to solve the problem.
>
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> >
> > Christoph

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