Removing and installing master cylinder: Audi TT Mk1

🧭 Before you start

Remove the air cleaner housing, clamp the supply hose with 3094, disconnect it and pull out the pipe/hose assembly after removing its clip, sealing the pipe end. Inside the car, remove the storage compartment, pedal switches if fitted and the complete pedal bracket. Take off the over-centre spring with T10111, remove the pedal stop and swing the cylinder out. On refitting, make sure the operating rod clip is on, the pedal locks, then bleed the clutch.

Fits: Audi TT Mk1 (8N)

• Opens: brake fluid, clutch fluid
• Special tools named: T10111

Don't miss

• Seal the end of the disconnected clutch pipe straight away so dirt and air stay out.
• The retaining clip must be fitted on the master cylinder operating rod before the pedal is engaged.
• Press the clutch pedal in until it engages, and confirm it is properly locked.
• Bleed the clutch system once the master cylinder is back in.
• Refit the clutch pedal switches F36 and F194 where fitted,.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Release hose clip (4) and detach intake hose and connector (1) from air mass meter.
2. Remove bolts (2) and (3).
3. If fitted, detach secondary air pipe (5) from air cleaner housing.
4. Then remove complete air cleaner housing.
5. Clamp off supply hose (A) coming from brake fluid reservoir using hose clamp3094.

6. Disconnect supply hose (A) at master cylinder.
7. Remove retaining clip (B) from master cylinder.
8. Pull pipe/hose assembly (C) out of master cylinder and seal end of pipe. [Note: In order to take out the master cylinder the entire clutch pedal assembly must be removed.]
9. Remove driver's storage compartment (bottom) 68.
10. If fitted, remove clutch pedal switch F36Removing and installing clutch pedal switch F36 (square housing) or Removing and installing clutch pedal switch F36 (round housing).
11. If fitted, remove clutch pedal switch for engine start F194 or Removing and installing clutch pedal switch for engine start F194.
12. Now remove complete clutch pedal mounting bracket as follows:
13. First remove connecting plate (arrow A)(arrows 1).
14. Then remove securing nuts (arrows 2) for mounting bracket (arrow B).
15. Take off mounting bracket.
16. Remove over-centre spring using assembly clip T10111 as follows:
17. Engage the lug (2) of the assembly clip into the cut-out on the over-centre spring.
18. Carefully pull clutch pedal towards you. At the same time, press both sides of retaining clip inwards using pliers T10005(arrows).
19. Turn stop (A) for clutch pedal in direction of arrow and remove.
20. Then push master cylinder in the direction of (arrow 1) onto stop.
21. Then swing master cylinder in direction of (arrow 3) out of mounting bracket.
22. Retaining clip (A) must be fitted on operating rod (B) of master cylinder.
23. Press clutch pedal in (direction of arrow) until it engages. Ensure that it is properly locked.
24. Fit stop (A) for clutch pedal again.
25. Install over-centre spring .
26. Bleed clutch system after installing master cylinder .
27. If fitted, install clutch pedal switch F36Removing and installing clutch pedal switch F36 (square housing) or Removing and installing clutch pedal switch F36 (round housing).
28. If fitted, install clutch pedal switch for engine start F194 or Removing and installing clutch pedal switch for engine start F194.
29. Install complete air cleaner housing 24.

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