Volkswagen Cars 2000-05

Slave (Actuator) Cylinder

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Disconnect the hydraulic line fitting(s) for the clutch slave cylinder.
  6.  
  7. From inside the transaxles bellhousing, remove the 3 clutch slave cylinder retaining bolts and remove the clutch slave cylinder.
  8.  
  9. Remove the clutch slave cylinder.
  10.  

To install:

  1. Installation is the reverse of removal.
  2.  
  3. Reconnect the negative battery cable.
  4.  
  5. Bleed the hydraulic clutch system, if required.
  6.  
  7. Check for proper clutch operation.
  8.  

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


NOTE
NEVER depress the clutch pedal while the slave cylinder is dismounted.

  1. Remove enough brake fluid from the reservoir until the level drops below the refill line connection.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Place a suitable drain pan under the slave cylinder.
  6.  
  7. Using a flare nut wrench loosen, but do not remove, the fluid line.
  8.  
  9. Remove the retaining bolts and pull the slave cylinder down.
  10.  
  11. Remove the line from the slave cylinder.
  12.  

To install:

  1. Install the slave cylinder on the transmission.
  2.  
  3. Tighten the slave cylinder bolts to 17 ft. lbs. (24 Nm).
  4.  
  5. Tighten the fluid connections to 12 ft. lbs. (16 Nm).
  6.  
  7. Make sure to install the cylinder with the bleed screw facing down. When installing the front pushrod, coat it with the proper high temperature grease.
  8.  
  9. Bleed the system.
  10.  

5 And 6-Speed 02m & 02y Transmissions

NOTE
The slave cylinder and release bearing are a single unit and are only replaceable as a unit.

  1. Refer to the accompanying illustration for Slave Cylinder Removal and Installation.
  2.  
  3. After installation, bleed the clutch system, as outlined in this section

    Click image to see an enlarged view

    Fig. Slave cylinder/release bearing removal and installation

  4.  

 
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