Volkswagen Workshop Service and Repair Manuals

Removing and installing slave cylinder Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331- Removing –  First check whether a coded radio is fitted. If so, obtain anti-theft code. –  With ignition switched off, disconnect battery earth strap → Electrical system; Rep. gr.27. –  Remove complete air filter housing if it hinders access to slave cylinder → Rep. gr.23 or → Rep. gr.24. –  Remove securing clip -arrow 1- for gear selector cable from gearbox selector lever -A-.

–  Pull gear selector cable off pin. Metal relay lever –  Remove securing clip -arrow 2- for gate selector cable from relay lever -B-. –  Pull gate selector cable from pin. –  Pull securing clip -arrow 3- off relay lever -B- and remove relay lever. Plastic relay lever –  Remove relay lever together with cable end-piece from gearbox → Chapter. Continuation for all –  Remove gearbox selector lever -A- by removing nut -arrow 4-.

–  Remove cable support bracket from gearbox -arrows-. –  Then raise and secure gear selector cable and gate selector cable. –  Remove retainer -B- from gearbox and pull it off pipe/hose line -A-.

–  Then remove gearbox support -arrow A-. –  Place a lint-free cloth under slave cylinder. –  Pull clip for pipe/hose line out of slave cylinder to stop. –  Pull pipe/hose line out of slave cylinder and seal opening. –  Remove slave cylinder -arrows B-.   Caution Do not operate clutch pedal any more. Installing Install in the reverse order of removal, observing the following:

–  Install slave cylinder and tighten bolts -arrows B- to specified torque. –  Insert pipe/hose line into slave cylinder to stop. –  Test pipe/hose line by tugging on it. –  Push retaining clip into pipe/hose line to stop. –  Then install gearbox support -arrows A-. –  Bleed clutch system after installing slave cylinder → Chapter. Assembling selector mechanism → Chapter. Adjust selector mechanism → Chapter. –  If removed, install complete air filter housing → Rep. gr.23 or → Rep. gr.24 –  Connect battery earth → Electrical system; Rep. gr.27. Specified torques Slave cylinder to gearbox → Item

Gearbox support to gearbox bracket and gearbox: –  Renew bolts. –  Screw in all bolts hand-tight. –  Tighten bolts to specified torque.

Bolts -arrows-

20 Nm + 90°