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

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

3184 Gearbox support
3184/1 Auxiliary support (to modify => Page
34-63
)
3227 Engine repair stand

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 engine support to engine block.

Hook auxiliary support 3184/1 for support device 3184 in cross panel (arrow). If necessary, remove wiring harnesses and pipes from cross panel.

Fit support device 3184 into auxiliary support 3184/1 and into subframe -A-. Screw spindle -C- into hole on engine mounting.
Align support device so that the slide -B- is resting against the right-hand tube (arrow).
Secure support device to subframe -A- and to auxiliary support 3184/1 by tightening the angle plates.
Relief subframe loading by raising engine/gearbox by means of spindle -C-.

Vehicles up to 12.95

Remove rear assembly mounting bolt (arrow).

Vehicles from 01.96

Remove pendulum support. To do this remove bolts -A- and -B-.

Continued for all vehicles

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 subframe mounting to subframe for vehicles up to 12.95 => Page
34-91

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 for vehicles up to 12.95 => Page
34-91

Mounting bracket to gearbox for vehicles from 01.96 => 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