Volkswagen Cars 2000-05

Master Cylinder

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The clutch master and slave cylinders should be replaced as a pair. If one unit fails, the other usually will fail soon after.

Removal & Installation





Click image to see an enlarged view

Fig. View of the brake/clutch master cylinder

  1. Remove the negative battery cable.
  2.  
  3. Detach the brake line from the master cylinder.
  4.  
  5. Cap off the open line.
  6.  
  7. Detach and cap off the supply line at the master cylinder.
  8.  
  9. Disconnect the relay plate from the left retainer.
  10.  
  11. Detach the pedal cluster protective plate.
  12.  
  13. Detach the master cylinder push rod from the pedal cluster.
  14.  
  15. Remove the mounting bracket support.
  16.  
  17. Remove the master cylinder.
  18.  

To install:

  1. Installation is the reverse of removal.
  2.  
  3. Do not forget to install the retainer on the master cylinder push rod.
  4.  
  5. Engage the retainer by depressing the clutch pedal
  6.  
  7. Thoroughly bleed the clutch master cylinder
  8.  

  1. Remove the necessary trim panel or carpet.
  2.  
  3. Disconnect the pushrod at the clutch pedal.
  4.  
  5. Remove the cap on the reservoir tank. On some vehicles, there is a clutch master cylinder reservoir, while on others there is a common reservoir shared with the brake master cylinder. Remove the float container, if equipped. Remove the screen and remove enough brake fluid from the tank until the level drops below the connection for the filler pipe.
  6.  
  7. On A4 and 1998-00 Passat models, detach the supply hose from the master cylinder reservoir and plug.
  8.  
  9. Remove the lower/left instrument panel trim. Then, detach the master cylinder actuating rod where it attaches to the pedal mechanism.
  10.  
  11. Remove the supply hose from the master cylinder and drain into a small, suitable container, and then plug the hose. Disconnect the line to the slave cylinder. Remove the retaining bolts and remove the master cylinder from the firewall.
  12.  

To install:

  1. Install the clutch master cylinder in position. Make sure all bushings remain in position.
  2.  
  3. Tighten the master cylinder mounting bolts to 6.5 ft. lbs. (9 Nm).
  4.  
  5. Tighten the fluid connections to 12 ft. lbs. (16 Nm).
  6.  
  7. Fill and bleed the system.
  8.  

5 And 6-Speed 02m & 02y Transmissions

NOTE
This procedure requires the following special tools and equipment, or their equivalents:



T10005 A Pliers
 

  1. If necessary, make sure you have the radio anti-theft code.
  2.  
  3. Make sure the ignition is OFF , then disconnect the negative battery cable.
  4.  
  5. Remove the intake hose, connector and hose from the Mass Air Flow (MAF) sensor.

    Click image to see an enlarged view

    Fig. Remove the intake hose (1), connector (2) and hose (3) from the mass air flow sensor. Unfasten the bolts (4, 5), then remove the air cleaner housing

  6.  
  7. Remove the complete air cleaner housing by removing the bolts.
  8.  
  9. Disconnect the supply hose from the brake fluid reservoir and plug or cap it.
  10.  
  11. Remove the clip that secures the line/hose to the master cylinder.
  12.  
  13. Pull the line/hose assembly from the master cylinder and cap or plug it.

    Click image to see an enlarged view

    Fig. View of the supply hose (A), clip (B) and line/hose assembly (C)

  14.  
  15. Remove driver's side lower cover(s).
  16.  
  17. Turn the clutch pedal switch 45° to the left, then pull it out from the support.
  18.  
  19. Separate the master cylinder operating rod from the clutch pedal as follows:
    1. Pull the clutch pedal lightly toward the passenger compartment.
    2.  
    3. Using pliers T10005 or equivalent tool, press both sides of the mounting inward.

      Click image to see an enlarged view

      Fig. Using pliers T10005 or equivalent tool, press both sides of the mounting inward

    4.  

  20.  
  21. Remove the clutch pedal support as follows:
    1. Remove the connecting plate first (arrows 1).
    2.  
    3. Remove the securing nuts (arrows 2) for mounting bracket.
    4.  
    5. Remove the mounting bracket.

      Click image to see an enlarged view

      Fig. Remove the connecting plate (A), then remove the nuts for mounting bracket (B)

    6.  

  22.  
  23. Turn stop (A) for clutch pedal in direction of arrow and remove.

    Click image to see an enlarged view

    Fig. Turn stop (A) for clutch pedal in direction of arrow and remove

  24.  
  25. Push master cylinder in direction of arrow (1) onto stop.
    NOTE
    The master cylinder must not be covered in upper area by over-center spring mounting (arrow 2).

  26.  
  27. Swing the master cylinder in direction of arrow (3) out of mounting bracket.

    Click image to see an enlarged view

    Fig. Removing the master cylinder from the mounting bracket

  28.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Fit retainer (A) to master cylinder operating rod -B-.

      Click image to see an enlarged view

      Fig. Fit retainer (A) to master cylinder operating rod -B-

    2.  
    3. Press clutch pedal in direction of arrow to engage and make sure it is in the proper position.

      Click image to see an enlarged view

      Fig. Press clutch pedal in direction of arrow to engage and make sure it is in the proper position.

    4.  
    5. Fit stop (A) for clutch pedal again. For the proper installed position, the arm (arrow) points toward master cylinder -B-.
    6.  
    7. Bleed the clutch system after installing master cylinder, as outlined in this section.
    8.  

  2.  

5-Speed 02j Transmission

NOTE
This procedure requires the following special tools and equipment, or their equivalents:



3309 Release tool
 
10-208 A Pliers
 

  1. Remove the intake hose, connector and hose from the Mass Air Flow (MAF) sensor.

    Click image to see an enlarged view

    Fig. Remove the intake hose (1), connector (2) and hose (3) from the mass air flow sensor. Unfasten the bolts (4, 5), then remove the air cleaner housing

  2.  
  3. Remove the complete air cleaner housing by removing the bolts.
  4.  
  5. Disconnect the supply hose from the brake fluid reservoir and plug or cap it.
  6.  
  7. Pry the clip for line/hose assembly out of master cylinder (direction of arrow in illustration).
  8.  
  9. Pull the line/hose assembly from the master cylinder and plug or cap it.

    Click image to see an enlarged view

    Fig. View of the supply hose (A), clip (B) and line/hose assembly (C)

  10.  
  11. Remove driver's side lower cover
  12.  
  13. Remove complete clutch pedal mounting bracket as follows:
    1. Remove connecting plate first (arrows 1).
    2.  
    3. Remove securing nuts (arrows 2) for mounting bracket.
    4.  
    5. Remove the mounting bracket.

      Click image to see an enlarged view

      Fig. View of the connecting plate (A), then remove the nuts for mounting bracket (B)

    6.  

  14.  
  15. Separate the master cylinder operating rod from clutch pedal as follows:
    1. Insert release tool 3309 in clutch pedal cut-outs (arrow A). Inscription "top/open" (-B-) points away from clutch pedal.
    2.  
    3. With pliers 10-208A positioned in recesses (arrow- C-), press release tool together.

      Click image to see an enlarged view

      Fig. Insert release tool 3309 in clutch pedal cut-outs (arrow A). Inscription "top/open" (-B-) points away from clutch pedal. With pliers 10-208A positioned in recesses (arrow- C-), press release tool together.

    4.  

  16.  
  17. Turn stop (A) for clutch pedal in direction of arrow and remove.

    Click image to see an enlarged view

    Fig. Turn stop (A) for clutch pedal in direction of arrow and remove

  18.  
  19. Push master cylinder in direction of arrow (1) onto stop.
  20.  
  21. Master cylinder must not be covered in upper area by over-center spring mounting (arrow -2-).
  22.  
  23. Swing master cylinder in direction of arrow (3) out of mounting bracket.

    Click image to see an enlarged view

    Fig. Removing the master cylinder from the mounting bracket

  24.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Fit retainer (A) to master cylinder operating rod (B).

      Click image to see an enlarged view

      Fig. Fit retainer (A) to master cylinder operating rod (B)

    2.  
    3. Press clutch pedal in direction of arrow to engage and make sure it is in the proper position.

      Click image to see an enlarged view

      Fig. Press clutch pedal in direction of arrow to engage and make sure it is in the proper position.

    4.  
    5. Fit stop (A) for clutch pedal again. For the proper installed position, the arm (arrow) points toward master cylinder (B).
    6.  
    7. Bleed the clutch system after installing master cylinder, as outlined in this section.
    8.  

  2.  

 
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