[s-cars] UrS4 Clutch Master Cylinder R&R How-to

[bill mahoney]

Mike,
It's not too difficult if you can work lying on your back upside
beneath the dash;)  Yes really.
I recall doing a btdt somewhere in the old yahoo groups if you care to search.
>From what  I recall,  remove the panels beneath the dash... taking
care how they come apart and note of how the courtesty light is
installed / attached.
You can then see just where the threaded shaft broke.  If it broke in
the middle I would just obtain or make a threaded coupling (two or
more nuts welded together,) attach both sides with some loctite and or
a small locking nut on each side and call it a day.
If it snapped off at the very end of the MC, you will need a new one
($140+-.)  This will require additional brake fluid, a motive pressure
 bleeder, a circlip removal tool, teeny tiny micro fingers and the
usual mix of misc. tools on hand.  Maybe put the wifes Yanni or James
Taylor CD in the stereo to relax you.  Play it loud so everyone won't
hear your swearing.
Prior to removing the MC, put a piece of plastic wrap under the
hydraulic fluid resevoir and tighten the cap back on.  This will
create a vacuum and keep brake fluid from going all over the place.
Have plenty of rags covering the footwell and on hand for spills.  IME
brake fluid is the nasiest of stuff and wash any skin contact
immediately.
You may notice that the bentley instructions call for a very specific
distance for the nut  to be set on the threaded shaft.. This will be
impossible to achieve so just get it close, taking care not to set it
too far out so that the piston crashes into the back of the cylinder
when depressing the clutch.
HTH
You can do ti!
Bill M