Clutch Master Cylinder Replacement

Clutch Master Cylinder Replacement - Audi UrS4 Clutch...

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Audi UrS4 Clutch Master Cylinder Replacement One of the “inevitable” UrS failures is the actuating rod on the clutch master cylinder. After a number of cycles, the rod snaps, the pedal goes to the floor, and you get to drive home in first gear, perfect your clutchless shifts, or call a flatbed – your choice. Mine failed around 227,000 kms. Verify the Failure There are several failures that could cause the clutch pedal to go to the floor. To verify the master cylinder rod has broken, remove the under dash heater vent and trim strip and the knee bar cover. Reach up under the left side of the pedal mount and check to see if the master cylinder rod is intact. If it has broken, the clevis will be loose on the pin at the pedal eye. Failure Mode The failed cylinder is shown in Photo 1. The rod is welded to a plate that is crimped into the large round boss at the end of the cylinder boot. This plate sits on a flat rubber ring located between the plate and the cylinder side of the boss. On my cylinder the rubber ring flowed out on one side, allowing the top plate to cock. This stressed the rod and resulted in a fatigue failure.
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Remove Old Cylinder 1. The clutch master cylinder is fed brake fluid from the brake master cylinder reservoir. The hose to the clutch master cylinder is connected to the left side of the reservoir. Remove the strainer from the filler spout on the reservoir and remove enough brake fluid to get the level below the hose to the clutch master cylinder. I used a MightyVac and a suction bottle
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This document was uploaded on 04/15/2009.

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Clutch Master Cylinder Replacement - Audi UrS4 Clutch...

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