Here’s a detailed guide to replacing the clutch slave cylinder on a Peugeot 806 2.2 HDI with a particle filter (WSRM). click here for more details on the download manual…..

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This process requires some mechanical knowledge and the right tools. Always ensure safety precautions are taken, and consult a repair manual for specific vehicle details.

### Tools and Equipment Needed
– **Wrench Set**: A complete metric wrench set will help in loosening and tightening the bolts.
– **Socket Set**: A ratchet and socket set, including both deep and shallow sockets, will be necessary for removing various components.
– **Torque Wrench**: To ensure bolts are tightened to the manufacturer’s specifications.
– **Pliers**: For removing clips and hoses.
– **Screwdrivers**: Both flathead and Phillips for various fasteners.
– **Brake Line Wrench**: A special wrench for loosening the hydraulic line without rounding off the fittings.
– **Fluid Catch Pan**: To collect any hydraulic fluid that may spill during the process.
– **Clutch Fluid**: New hydraulic fluid (usually DOT 4) for refilling the clutch system after the replacement.
– **Rags or Shop Towels**: For cleaning up spills and wiping down components.
– **Jack and Jack Stands**: To lift the vehicle and secure it safely while you work underneath.
– **Safety Glasses and Gloves**: To protect your eyes and hands during the replacement.

### Replacement Steps

– **Preparation**:
– Park the vehicle on a flat surface and engage the handbrake.
– Disconnect the negative terminal of the battery to prevent any electrical shorts.

– **Accessing the clutch Slave Cylinder**:
– Raise the front of the vehicle using a jack and secure it with jack stands.
– Remove the undertray or any protective covers that obstruct access to the transmission.

– **Removing the Transmission Fluid**:
– Place a fluid catch pan under the transmission and drain the transmission oil if necessary to access the slave cylinder without spilling.

– **Locating the clutch Slave Cylinder**:
– Identify the clutch slave cylinder, typically located on the side of the transmission, attached to the clutch assembly.

– **Disconnecting the Hydraulic Line**:
– Use a brake line wrench to carefully loosen and disconnect the hydraulic line from the slave cylinder. Allow any residual fluid to drain into the catch pan.

– **Removing the Slave Cylinder**:
– Unbolt the slave cylinder from its mounting point using the appropriate socket or wrench. Keep track of the bolts and their locations.
– Gently pull the slave cylinder away from the transmission. Be cautious of any remaining hydraulic fluid.

– **Preparing the New Slave Cylinder**:
– check the new slave cylinder for any defects. Ensure it is the correct part by comparing it with the old one.
– If necessary, pre-fill the new slave cylinder with hydraulic fluid to minimize air in the system upon installation.

– **Installing the New Slave Cylinder**:
– Position the new slave cylinder in place and secure it with the bolts. Ensure it is seated correctly against the transmission.
– Tighten the bolts to the manufacturer’s specified torque using a torque wrench.

– **Reconnecting the Hydraulic Line**:
– Reattach the hydraulic line to the new slave cylinder, ensuring not to cross-thread it. Tighten securely.

– **Refilling the clutch Hydraulic System**:
– Fill the clutch reservoir with new hydraulic fluid. check for any leaks at the slave cylinder and hydraulic line connection.

– **Bleeding the clutch System**:
– Bleed the clutch system to remove any air trapped in the hydraulic lines. This can typically be done using a helper to pump the clutch pedal while you open and close the bleed valve on the slave cylinder.

– **Reassembling the Vehicle**:
– Reinstall any undertrays or protective covers removed earlier.
– Lower the vehicle back to the ground and reconnect the negative battery terminal.

– **Testing**:
– Start the vehicle and test the clutch operation. Ensure it engages and disengages smoothly without any abnormal noises or resistance.

– **Final Checks**:
– check for any leaks around the slave cylinder and hydraulic line after a short test drive. Ensure that the clutch operates correctly under normal driving conditions.

### Final Notes
– If you are unsure about any steps or the process, it may be wise to consult with a professional mechanic or refer to the specific Peugeot service manual for detailed instructions and specifications.
– Always dispose of any used fluids responsibly according to local regulations.
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