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Volkswagen Cars 2000-05
The clutch master and slave cylinders should be replaced as a pair. If one unit fails, the other usually will fail soon after.
Fig. View of the brake/clutch master cylinder
5 And 6-Speed 02m & 02y TransmissionsNOTE This procedure requires the following special tools and equipment, or their equivalents: T10005 A Pliers
Remove the clutch pedal support as follows:
Turn stop (A) for clutch pedal in direction of arrow and remove
FIG : Turn stop (A) for clutch pedal in direction of arrow and remove
Press clutch pedal in direction of arrow to engage and make sure it is in the proper position.
FIG : Press clutch pedal in direction of arrow to engage and make sure it is in the proper position.
5-Speed 02j TransmissionNOTE This procedure requires the following special tools and equipment, or their equivalents: 3309 Release tool 10-208 A Pliers
Separate the master cylinder operating rod from clutch pedal as follows:
Turn stop (A) for clutch pedal in direction of arrow and remove.
The clutch and brake hydraulics use an approved DOT 4 brake fluid in their systems. The hydraulic system should be bled periodically, usually a minimum of every two years, or more often under severe use. Brake fluid can absorb moisture. Because condensation is heavier than brake fluid, and under normal conditions, will not mix with it, the sediment and condensation tend to collect in the slave cylinder and in the bottom of the master cylinder reservoir.
If possible, before bleeding the system, use a siphon gun or a cooking baster to remove the old fluid, or remove the reservoir and flush it using a recommended brake cleaner or rubbing alcohol. If necessary, the reservoir can be flushed while removed from the vehicle using lightly pressurized water, however the reservoir must be flushed with brake cleaner or rubbing alcohol and dried completely before installation.
There are a number of brake hydraulic bleeders available that use vacuum to 'pull' the fluid through the hydraulic system. The advantage these tools offer is that the system can be bled without the help of an assistant.
CAUTION Bleeding or flushing the clutch hydraulic system with dirty or contaminated fluid may result in component damage.
When bleeding a clutch hydraulic system, always observe to following guidelines:
NEVER reuse brake fluid Always bleed the system using fresh fluid Do NOT use fluid which has been left uncapped Use a recommended fluid which is compatible with the existing fluid
Fig. A vacuum tester and a bleeding attachment (shown bleeding the brakes here) eliminate the need for a helper. These units are available from automotive vendors