Removing and installing slave cylinder for vehicles with long front end — VW

Special tools, workshop equipment, test and measuring appliances and aux. items required

10-222 A Support
10-222 A/2 Auxiliary hooks
10-222 A/6 Supports
10-222 A/7 Auxiliary hooks
2024 A/2 Lifting eye

Removing

Loosen hexagon bolts (arrows) for securing selector housing.

The selector housing must be able to move, if necessary remove bellows frame and gear lever boot.

Remove noise insulation tray below engine/gearbox.

Fit support device 10-222A in conjunction with hooks 10-222 A/6.
Hook additional hook 10-222 A/7 in bracket on engine.
Pretension engine/gearbox assembly via spindles.

On vehicles with 5 cylinder injection engine, pull connector off spark plug for No. 2 cylinder and bolt lifting eye 2024 A/2 onto engine block in addition.

A - 2 mm thick washer

Remove pendulum support -1-; to do this, remove bolts -arrow A- and -arrow B-.

Unbolt (arrows) mounting bracket -A- from gearbox.
Lower gearbox via support device spindle.

Note:

When lowering, beware of restricted areas, propshaft/subframe and front exhaust pipe/anti-roll bar. Do not damage surface areas, separate propshaft or exhaust pipe if necessary.

Remove pipe/hose and bolts for securing slave cylinder (arrows).
Take off slave cylinder.

Installing

Installation is carried out in the reverse sequence, when doing this note the following:

Bleed clutch system after installing slave cylinder=>Page
30-23
.

Tightening torques

Rear gearbox mounting for vehicles from 01.96

=> Axles, steering, suspension from January 1996; Repair group 40; I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone and shock absorber
Axles, steering, suspension from January 1996
I - Removing and installing subframe, anti-roll bar, torsion bar, wishbone and shock absorber

Note:

Install engine/gearbox mountings stress-free.

=> Repair group 10; Removing and installing engine.
5-speed manual gearbox 02D four-wheel drive
Removing and installing engine.

Mounting bracket to gearbox => Page
34-91

Gearstick housing to floor plate => Page
34-5
, item
8

Slave cylinder to gearbox => Page
30-9
, item
14

Pipe/hose to slave cylinder => Page
30-9
, item
9