Clutch Release Mechanism, Servicing

Clutch release mechanism, servicing






1. Slave cylinder
After removing, do not operate clutch pedal
Installing, refer to Fig. 1
When installing, push in until the securing bolt -item 2- can be installed
Tighten bleeder valve to 4 Nm
Bleeding clutch system, refer to Service and Repair - Procedures Service and Repair

2. Hex socket head bolt, 20 Nm
Slave cylinder to transmission
Self-locking
Always replace

3. Bracket
For line/hose assembly
Secured to transmission with slave cylinder

4. Plunger
Coat end of plunger with copper grease

5. Dished washer
Smaller diameter (convex side) to guide sleeve

6. Input shaft oil seal
Pull out of guide sleeve with oil seal extractor lever VW 681
Knock in onto stop with fitting sleeve VW 192

7. Torx socket head bolt
Self-locking
Always replace
Black; only for aluminium transmissions
Bright; for aluminium and magnesium transmissions
For aluminium transmissions 35 Nm
For magnesium transmissions 25 Nm

8. Release bearing
Do not wash-out bearing, only wipe
Replace noisy bearings

9. Clutch release lever
Before installing, thinly coat contact surface of slave cylinder plunger with copper grease

10. Retaining spring
Secure to clutch release lever

11. Guide sleeve
Before pulling off or pressing on, pull shrink tube over input shaft splines to protect oil seal -item 6-
Installation position: oil drain hole facing downwards
Guide sleeve made of different materials for aluminium and magnesium transmissions

12. O-ring
Always replace

13. Intermediate-piece

14. Ball stud
Lubricate with MoS2 grease
Ball studs made from different materials for aluminium and magnesium transmissions
For aluminium transmissions 25 Nm
For magnesium transmissions 20 Nm

15. Transmission

Fig. 1 Installing clutch slave cylinder






- Lightly coat plunger surface contacting clutch release lever.
- Before slave cylinder is installed in transmission housing, region -a- of boot must be coated with lithium grease G 052 150 A2.
- Guide slave cylinder into fitting hole of transmission housing without great lateral deviation from working direction of operating rod and bolt securely.

Notes: Preload slave cylinder sufficiently so that the securing bolt can easily be inserted.
Brake fluid must not come in contact with transmission. If necessary, clean transmission housing.






- To connect line/hose assembly to slave cylinder, you must press clip -A- to stop.
- Insert line/hose assembly in slave cylinder until line audibly engages.
- Bleed clutch system, refer to Service and Repair - Procedures Service and Repair