Smoothie
Joined: 01 Jan 2003
Posts: 8032
Location: DE (the one near MD, PA, NJ)
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 Posted: Sat May 08, 2004 12:15 pm Post subject: Clutch slave cylinder rebuild, bench bleeding and reinstall |
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New rebuild kit contents on the left (rubber bellows, retainer ring, seal, bleeder cover) and old parts on the right -
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Inside of slave cylinder after cross-hatch patterning with a brake cylinder hone -
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Removal of the old seal with a pick (be careful not to scratch the groove that the seal fits into) -
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Old seal (center) and new seal (right). Big difference! -
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New seal installed and with assembly lube smeared all over -
(I used assembly lube that was left-over from a brake MC rebuild kit.)
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Assembly order -
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Bench Bleeding -
I cut the end off a gearbox fluid bottle cap to use as a funnel. When cut at the right point, it can be screwed right into the slave cylinder -
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Funnel attached -
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Start with the plunger pushed all the way in, then fill through the funnel and continue filling while slowly letting the plunger back out. Then push in slowly with short strokes to expell any remaining bubbles while keeping the funnel about half-full. Then reposition the cylinder, tilting it slightly, and repeat to expell any more bubbles. -
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Reattaching to the car... before engaging the slave cyl rod into the clutch fork, I reattach the hydraulic line. -
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...then place slave cyl rod into the clutch fork -
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Then push the slave cyl in and tighten down the bolts - and give the hydraulic line connection a final tightening. -
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Then I skip the annoying bleed process and instead, pump the clutch pedal by hand quickly - after about 40-50 pumps it starts to come back and after about 70-80, it's back. Then pump a few times by foot and it's done. 
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"..it's made in Germany. You know the Germans always make good stuff."
'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox |
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