[Es2] [audi20v] Re: 91 CQ - Brake fluid low - Clutch?
pcschulz at comcast.net
Wed Aug 9 14:24:16 EDT 2006
Recently replaced BOTH the clutch and slave in trying to resolve a
low pedal issue.
Replaced the slave first, of course issue ended up being the master,
which by the way had no external leakage.
You can replace the master without jacking up the car, but it is
easier to access the slave to bleed it later...
To R&R the master ...
You may want to put some penetrant ( Pb Blaster, Kroil, etc on the
flare nut fitting on the engine side of the Clutch Master cylinder a
day or two before starting the R&R)
from the interior - remove the kick panel or shelf on the driver's
side. Put down some cardboard/plastic to protect the rug from grease
and brake fluid.
remove the circlip holding the pin on the clevis at the end of the
from the engine compartment:
Use a turkey baster or other means to reduce the level of brake fluid
in the reservoir BELOW the level where the supply line to the clutch
master enters ( rubber hose exiting the Brake fluid reservoir close
to the firewall)
clamp off the hose close to the reservoir using a pair of radiator or
hose pliers ( before removing to keep the brake fluid trapped in the hose)
remove the two 10 mm nuts holding the cruise control mechanism to the
bracket and swing it out of the way ( may have to disconnect a vacuum
hose)...remove the 10mm nut holding the bracket with 4 connectors on
it ( two are the knock sensors)
You should now have limited access to the rigid line off the back of
the clutch master...using a 12mm? flare nut wrench, loosen and remove
the line ( removing and reinstalling this took by far the most time,
access limited me to only having 1/8 to 1/4 turn reach for the
wrench. be patient and take your time) Before completely removing
put a small cup underneath the line to catch the fluid, if any comes out.
Back to the interior...remove the two allen bolts holding the clutch
master to the pedal assembly. carefully pull the master down and
towards you, the rubber boot on the firewall should come along with
the rubber hose and clutch master. Over a container to catch any
residual brake fluid, remove the rubber hose and connect it to the
new clutch master, do the same with the firewall rubber boot. Measure
the distance on the old Master from the nut to the clevis and
replicate the position on the new master.
Installation is reverse of removal.
Note, you want to "reverse bleed" the clutch master and slave...that
means you want to PUSH brake fluid into the bleeder on the clutch
master. Access the slave bleeder screw, either from above or through
the driver's wheel well pretty much stinks. I ended up loosening it
through the wheel well with a 6 pt deep socket, then accessed it from
above with a 11mm flare nut wrench I cut in half to make it a stubby wrench.
Some folks use a hose from the drivers brake caliper bleeder to the
clutch slave bleeder and by pumping the brake, force fluid under
pressure from the brake caliper into the slave...the fluid then
travels through the slave up to the Master and then ultimately into
the reservoir. Instead of doing this, I used my motive pressure
brake bleeder, remove the hose with the Brake fluid reservoir cap and
replaced it with a section of clear vinyl hose from a hardware store,
put about half a liter of fluid into it, pressurized it to about
15psi, opened the clutch slave bleeder and let it run...while
watching the brake reservoir fill. Be patient and careful when doing
this, can be messy and the brake fluid can eat paint.
Biggest lesson learned, if you EVER have to take the engine of the
car ( transplant etc), you may want to consider replacing the master
and slave then, because you will never that kind of access again
..Fat wallet syndrome be damned..
At 01:46 PM 8/6/2006, you wrote:
>Well, I just noticed fluid leaking out of the rear rubber boot on the end
>of the clutch master cylinder.
>Any one replaced one of these?
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Chelmsford Ma, USA
1991 200 20v Q Avant Titan Grey
1991 200 20v Q Avant Indigo Mica
1991 90 20v Q Red
1990 CQ silver (awaiting S2 engine transplant)
1991 CQ silver (potentially replacing the 1990 for the transplant)
1990 CQ red ( to part or not)
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