Service

Workshop Manual
Gol 2009 ➤
Fox 2004 ➤
Troubleshooting, Mechanical Transmission
Edition 04.2008

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Service Department. Technical Information

 Service
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List of Workshop Manual Repair Groups
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Repair Group
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urposes, in part or in wh

30 - Clutch - control system

t to the co
34 - Drive, housing

rrectness o
cial p

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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg BRA5R046120

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Contents

30 - Clutch - control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Complaints related to clutch
AG.and
Volksclutch
wagen Acontrol .................................. 1
agen G do
es n
1.1 Checking the clutch
yV
ol drive
ksw . . . . . . . . . . . . . . . .
ot g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 10
b ua
ed ran
ris
34 - Drive, housing ....................... . . . . . o.r . . . . . . . . . . . . . . . . . . . . . . . 12
o tee
th
au ac
1 ss
Complaints related to the selection mechanism .................................. 12

ce
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or

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ate

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Contents i
 Gol 2009 ➤ , Fox 2004 ➤ n AG. Volkswagen AG do
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Troubleshooting, Mechanical Transmission
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ii Contents
 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

30 – Clutch - control system

1 Complaints related to clutch and
clutch control

Note

Checking the clutch drive ⇒ page 10 .

Before carrying out any repairs on the clutch, it is always neces‐

sary to check the customer's complaint and trace the problem
cause. When doing this, check whether the complaint is related
to the clutch or the selection mechanism adjustment is causing
the problem.
Repair action indicated in this troubleshooting programme must
be carried out as described in the respective repair manuals.
Complaints Fault description Corrective action
The clutch pedal does not return to ♦ Air in the clutch system pipes, – Top up the reservoir with brake
its initial position. low brake fluid reservoir level olksw fluid, and bleed the clutch sys‐
agen
AG. V tem. does
agen AG
olksw not
♦ The master cylinder
edb
y V
or the slave – Replace defective
gu
ara parts, bleed
cylinder are
ho
risgetting stuck. clutch system. nte
e t or
au ac
♦ Pipes,ssmaster cylinder or slave
cylinder are leaking

ce
le
un

pt
an
d
itte

y li
♦ Return spring (if incorrectly fit‐
– Reposition the return spring.
erm

ab
ted). Replace the return spring, if nec‐

ility
ot p

essary.

wit
is n

h re
♦ Actuator elements in the clutch – Clean and lubricate actuators.
ole,

spec
case are gripped. Replace actuators, if necessary.
urposes, in part or in wh

t to the co
♦ The clutch bearing is askew in – Replace guide tube and clutch
the guide tube, causing wear. bearing.

rrectne
♦ The diaphragm spring for the – Replace the clutch plate.
clutch plate pressure plate is
s
broken. s o
cial p

f inform
mer

atio
om

Complaints Fault description

c

Corrective action
i
or

n thi
te

The drive pressure on the clutch ♦ The clutch pedal is getting stuck. – Clean and lubricate the bear‐
sd
iva

o
r

pedal is very high ings. Replace the bearings, if

p

cum
r

– Before checking, separate the

fo

necessary.
en
ng

master cylinder from the clutch

t.
yi Co
op
pedal. C py
t. rig
gh ht
yri
♦ The limiting spring's housing is – Clean and lubricate the housing.
p by
o Vo
by c lksw
getting stuck; the limiting spring Replace the housing if necessa‐
Prote
cted agen
is defective ry. Replace the limiting spring.
AG.

♦ Return spring, if incorrectly ad‐ – Reposition return spring.

justed (very strong).

1. Complaints related to clutch and clutch control 1

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

♦ The clutch's release pressure – Explain the situation to the cus‐
increases due to wear of pack‐ tomer (the release pressure
ings (linings) of the clutch disc. grows as wear increases)

– Replace the clutch disc if the

distance between the disc sur‐
face and the rivet is less than 0.1
mm
♦ The actuator element in the – Clean and lubricate actuators.
clutch case is getting stuck. Replace actuators, if necessary

♦ The clutch bearing is askew in – Replace the defective parts.

the guide tube, causing wear.
AG. Volkswagen AG d
agen oes
ksw not
♦ The contact surface bbetween
yV
ol
– Replace the defective gu parts.
ara
the clutch bearing ris and the re‐
ed
nte
lease lever isaworn/marked
ut
ho eo
ra
ss c

ce
le

♦ The plate's pressure plate – Obtain the appropriate part ac‐

un

pt
spring has incorrect specifica‐ cording to the ⇒ Electronic parts

an
d
itte

y li
tion. catalogue .
erm

ab
ility
ot p

♦ The clutch disk gets stuck / is – Check possible damage in the

wit
is n

stuck in the hub groove. hub grooves (burrs). Replace

h re
ole,

the clutch disc, if necessary.

spec
urposes, in part or in wh

t to the co
– Remove corrosion and lubricant
deposits in the hub splines and
the input shaft splines, and lu‐

rrectne
bricate with grease -G 000 100- .
See the ⇒ Chemicals Manual .
Displace the clutch disc for‐

ss
wards and backwards, and re‐

o
cial p

f
move excess grease.

inform
mer

atio
om

n
c

i
or

n
Complaints Fault description Corrective action

thi
te

sd
va

Noise when step‐ ♦ Clutch pedal – Clean and lubri‐

i

o
pr

cum
r

ping on the clutch gets stuck, cate the bear‐

fo

en
ng

points are out of ings. Replace

t.
yi Co
op
alignment. the bearings, if C py
t. rig
necessary.
gh ht
yri
♦ Limiting spring
p by
o Vo
by c lksw
dry, stuck or mis‐ Prote
cted AG.
agen
aligned

♦ The return spring – Grease the bear‐

(if incorrectly in‐ ing points.
stalled) makes
noises.

♦ Defect in the – Always replace

clutch release noisy release
bearing; the re‐ bearings.
lease bearing's
guide tube is not – Replace the
OK; contact sur‐ guide tubes if
face is worn. damaged.

2 Rep. Gr.30 - Clutch - control system

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

♦ Defect in the – Replace the
contact surface clutch plate.
(diaphragm
spring ends) of – Check and, if
the plate's pres‐ necessary, re‐ AG. Volkswagen AG d
sure plate (bent, place the clutch agen oes
olksw not
broken). Clutch bearing and d bythe
V gu
ara
bearing decen‐ guide tube.o rise nte
eo
tralised. aut
h
ra
c
– Check
ss
the re‐

ce
e
lease lever's po‐

nl

pt
du
sition.

an
itte

y li
erm

ab
– Check the cen‐

ility
ot p
tralisation pins.

wit
, is n

h re
♦ Defect in the – Replace and lu‐
hole

spec
crankshaft nee‐ bricate with
es, in part or in w

dle bearing (if fit‐ MoS2 grease.

t to the co
ted). Engine/
transmission – Check the cen‐
misaligned. tralisation pins.

rrectness of i
♦ Clutch disc in‐ – Correct the in‐
l purpos

correctly instal‐ stallation posi‐

led. tion.

nf
ercia

orm
♦ The wrong clutch – Obtain the ap‐
m

atio
m

disc was instal‐ propriate clutch

o

n in
c

led. disc according to

or

thi
e

the ⇒ Electronic
t

sd
iva

parts catalogue .

o
r
rp

cu
o

m
f

en
ng

Complaints Fault description Corrective action

t.
yi Co
Cop py
.
There are noises ♦ The brake fluid – Check the sys‐
ht rig
rig ht
by
when a forward or level is too low. tem, top up copy Vo
by lksw
reverse gear is se‐ brake fluid, bleed cted agen
Prote
lected; the selection ♦ There is air in the
AG.
the system.
mechanism gets system, the
stuck; it is not possi‐ clutch did not
ble to select a gear; come out com‐
the clutch does not pletely.
work
♦ Leak in the mas‐ – Replace the de‐
ter/slave cylinder fective part, top
and tubes, line is up brake fluid,
too elastic. and bleed the
system.
♦ Clutch pedal has – Explain the sit‐
not enough trav‐ uation to the cus‐
el (carpet or mat tomer.
under pedal), the
clutch is not
completely de‐
pressed.

1. Complaints related to clutch and clutch control 3

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

♦ Plate's pressure – Check parts, re‐
plate is uneven place as neces‐
due to defective sary, check the
installation; position of the
clutch disc is centralisation
bent due to in‐ pins.
correct handling.
– If the problem
persists, check
the clutch disc
hub splines in
the input shaft for
ease of move‐
ment; check the
crankshaft nee‐
dle bearing; car‐
ry out repairs to
the transmission,
if necessary.
♦ Clutch plate – nReplace
AG. Volkswthe
agen AG
wage does
spring endsy Vbro‐ olks clutch plate. not
gu
ken or bent ised b (de‐ ara
nte
fective horinstalla‐ – Check and, if eo
ut
tion,
ss a clutch bear‐ necessary, re‐ ra
c
ing misaligned). place the clutch

ce
e
nl

bearing and the

pt
du

an
guide tube.
itte

y li
erm

ab
ility
– Check the cen‐
ot p

wit
tralisation pins.
, is n

h re
hole

♦ The clutch disc is – Obtain the ap‐

very thick. propriate clutch spec
es, in part or in w

disc according to t to the co

the ⇒ Electronic
parts catalogue .
rrectness of i

♦ Packing (lining) – File lightly the

gripped/locked clutch disc's fric‐
l purpos

on the flywheel tion surfaces or,

(parked for a if there is a lot of
long time, high corrosion, re‐
nform
ercia

humidity level). place the part.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4 Rep. Gr.30 - Clutch - control system

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

♦ Clutch disc gets – Check possible
stuck in / ad‐ damage in the
heres to the hub grooves.
groove. Corro‐ Replace the
ded hub, dam‐ clutch disc, if
aged during in‐ necessary.
stallation. Hub
profile mis‐ – Remove corro‐
aligned on one sion and grease
side. deposits from
the hub and from
the shaft. Lightly
lubricate the
shaft with graxa -
G 000 100- .

– Displace the
clutch disc for‐
wards and back‐
wards, and re‐
move excess
grease.

– Check the posi‐

tion of the cen‐
tralisation pins if
the hub profile is
misaligned.
gen AG
. Volkswagen AG
d
a oes
ksw not
Vol
– edCheck
by and, if gu
ara
oris necessary, re‐ nte
eo
th
au place the clutch ra
c
ss bearing, the

ce
le

guide tube, the

un

pt
an
d

clutch plate and

itte

y li
the needle bear‐
erm

ab
ility
ing.
ot p

wit
is n

♦ The plate's pres‐ – Obtain the ap‐

h re
ole,

sure plate does propriate clutch

not lift high plate according spec
urposes, in part or in wh

enough (incor‐ to the ⇒ Elec‐ t to the co

rect clutch plate). tronic parts cata‐
logue .
rrectne

♦ Defect in the – Replace the nee‐

crankshaft nee‐ dle bearing and
dle bearing (if fit‐ lubricate with
ss

ted). The input MoS2 grease.

o
cial p

shaft is lifted by
in

Refer to the ⇒
form

the crankshaft Chemical Man‐

mer

whenever the
atio

ual
m

clutch is de‐
o

n
c

i
or

pressed. – Check the cen‐

thi
te

sd

tralisation pins.
iva

o
pr

cum
r
fo

– Check the input

en
ng

t.
yi
shaft.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Complaints related to clutch and clutch control 5

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

♦ Engine/trans‐ – Insert the cen‐
mission exces‐ tralisation pins
sively misaligned before installing
(no centralisa‐ the transmission.
tion pins), caus‐
ing the clutch – Check the clutch
disc support disc, the plate's
plate to bend. pressure plate
Defect in the and the needle
crankshaft nee‐ bearing for dam‐
dle bearing (if fit‐ age, and replace
ted). as necessary.

♦ Packings (lin‐ – Replace the

ings) displaced clutch disc. Ex‐
due to excessive plain the situa‐
speed (shifting tion to the cus‐
downwards at tomer.
very high
speed).
♦ Packings are
displaced be‐
cause the clutch
skids too much
as it pulls away.
. Volkswag
AG en AG
agen does
olksw not
byV gu
Complaints rised Fault description Corrective action
ara
nte
ho eo
aut
The load assembly ♦ The assembly is – Explain the sit‐
ra
s c
vibrates when
s the fitted very loose‐ uation to the cus‐
ce
e

engine speed accel‐ ly. tomer. Obtain

nl

pt
du

an

erates or deceler‐ the appropriate

itte

y li

ates suddenly assembly ac‐

erm

ab
ility

cording to the ⇒
ot p

Electronic parts
wit
, is n

h re

catalogue , re‐
hole

place if necessa‐
spec

ry.
es, in part or in w

t to the co

♦ The engine oscil‐ – Check and cor‐

lates (does not rect the engine
operate smooth‐ assembly.
rrectness of i

ly).
l purpos

♦ The clutch disc is – Explain the sit‐

installed with a uation to the cus‐
nform
ercia

defective ab‐ tomer.

sorber spring (to
m

at
om

prevent loose
ion
c

gears from oscil‐

in t
or

his
e

lating).
at

do
priv

cum
or

♦ Defect in the – Replace the nee‐

f

en
ng

crankshaft nee‐ dle bearing and

t.
yi Co
op
dle bearing (if fit‐ lubricate with
C py
ht. rig
ted). Engine/ MoS2 grease.
rig ht
py by
transmission
co Vo
by lksw
cted agen
Prote misaligned. AG.
Refer to the ⇒
Chemical Manual
– Check the cen‐
tralisation pins,
and replace as
necessary.

6 Rep. Gr.30 - Clutch - control system

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

The clutch skids, ♦ The plungers ofAG. –VolkReplace
swagen AGthe
agen does
with no or little pro‐ the master
Volksw and master/slave cyl‐
not g
pelling slave
ed b cylinders
y inders. ua
ran
hordo
i not return to
s tee
aut their initial posi‐ – Replace the or
ac
ss tion. brake fluid, and

ce
e
bleed the sys‐
nl

pt
du

an
tem.
itte

y li
erm

ab
♦ Incorrect clutch – Obtain the ap‐

ility
ot p

disc, incorrect propriate clutch

wit
, is n

clutch plate. disc and clutch

h re
plate according
hole

spec
to the ⇒ Elec‐
es, in part or in w

tronic parts cata‐

t to the co
logue .
♦ Clutch disc worn – Replace the

rrectness of i
or burnt; plate's clutch disc.
pressure plate
l purpos

overheated, – Replace the

scratched; clutch plate.
plate's pressure

nf
ercia

o
plate bent due to – Explain the sit‐

rm
m

defective instal‐ uation to the cus‐

atio
m

lation, insuffi‐ tomer.

o

n in
or c

cient contact

thi
e

pressure on the
t

sd
iva

o
plate's pressure
r
rp

cu
o

m
plate, steering
f

en
ng

t.
fault, normal
yi Co
op
wear.
C py
t. rig
gh ht
pyri by
Vo
co
♦ Elements of the – Clean and lubri‐
by lksw
cted agen
Prote
actuator in the cate the bear‐
AG.

transmission are ings. Carry out

getting stuck. the necessary
The pedal mech‐ repairs.
anism is hard.

♦ Clutch disc, – Replace the

plate's pressure clutch disc.
plate, flywheel
have oil in ex‐ – Clean the con‐
cess. The seal‐ tact surfaces, the
ing of the engine plate's pressure
or transmission plate and the fly‐
shaft is defec‐ wheel.
tive. There is
grease on the – Replace shaft
contact surfaces sealing, remove
due to excess excess grease
grease in the from the input
hub. shaft.

♦ Clutch disc in‐ – Correct installa‐

correctly instal‐ tion, check
led. clutch disc, and
replace if neces‐
sary.

1. Complaints related to clutch and clutch control 7

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

♦ The flywheel is – Obtain the ap‐
very worn or propriate fly‐
there is too much wheel according
erosion on the to the ⇒ Elec‐
packing's con‐ tronic parts cata‐
tact surface. logue .

– Check the clutch

disc and the
clutch plate, and
replace as nec‐
essary.
AG. Volkswagen AG d
♦ Slave cylinder, – Replace the agen oes
olksw not
clutch bearing slave cylinder d by
V gu
ara
are leaking. with the clutch orise nte
eo
bearing. au
th
ra
ss c

ce
le
Complaints Fault description Corrective action un

pt
an
d
itte

y li
The clutch vibrates, ♦ There is air in the – Replace the de‐
rm

ab
the assembly vi‐ system, master/ fective part.
pe

ility
brates slave cylinder is
ot

wit
, is n

defective. – Check brake flu‐

h re
id level, bleed
hole

spec
the system,
es, in part or in w

check for leaks.

t to the co
♦ The engine does – Check and cor‐
not operate rect the engine

rrectness of i
properly assembly/instal‐
lation.
l purpos

♦ Drive fault, pull‐ – Explain the sit‐

ing away speed uation to the cus‐

nform
ercia

very low. tomer.

m

a
com

ti
♦ The wrong clutch – Obtain the cor‐

on in
disc was instal‐ rect clutch disc
r
te o

thi
led. according to the

s
iva

do
⇒ Electronic
r
rp

cum
parts catalogue .
fo

en
ng

t.
yi
♦ The assembly is – Obtain the ap‐
Co
op py
very loosely fit‐ propriate assem‐
t. C rig
gh ht
yri
ted and mis‐ bly according to p by
o Vo
by c
aligned. the ⇒ Electronic
lksw
cted agen
Prote
parts catalogue .
AG.

♦ Clutch packing – Check the seal‐

(lining), plate's ing of the trans‐
pressure plate mission input
contact surface shaft or of the
and flywheel crankshaft, and
have excess oil replace as nec‐
(oil leaking from essary.
the clutch case).
– Replace the
clutch disc, clean
the plate's pres‐
sure plate and
the flywheel.

8 Rep. Gr.30 - Clutch - control system

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

♦ The clutch bear‐ – Replace the
ing is askew in clutch bearing
the guide tube, and the guide
gripped (pres‐ tube.
sure on one side
on the clutch – Check the actua‐
plate diaphragm tor elements and
spring). their bearings.

♦ The contact sur‐ – Check the con‐

face for the tact surface of
plate's pressure the clutch pack‐
plate only lifts on ing with the fly‐
one side due to wheel, the
the skewed posi‐ plate's pressure
tion of the re‐ plate and the di‐
lease bearing. aphragm spring;
replace the
♦ The housing for clutch plate if
the plate's pres‐ necessary.
sure plate got
bent during as‐ – Replace the
sembly. The clutch bearing
contact surface and the guide
AG. Volkswagen AG
of the plate's l
agen
kswtube.
does
not
pressure plated by Vo gu
ara
has only one orise nte
eo
side lifted
aut up.
h
ra
ss c

ce
le

♦ The input shaft – Clean the grease

un

pt
an
has excess from the plate's
d
itte

y li
grease (traces of pressure plate
rm

ab
pe

grease on the and from the fly‐

ility
ot

clutch disc, wheel, and re‐

wit
, is n

plate's pressure place if there are

h re
hole

plate and fly‐ signs of damage

spec
wheel). (vibration marks,
es, in part or in w

overheating t to the co
signs, scratch‐
es).
rrectness of i

– Remove grease
l purpos

traces from the

hub and from the
shaft; lightly lu‐
nform
ercia

bricate the shaft

m

with grease -G
a
com

tio

000 100- . Refer

n in

to the⇒ Chemi‐
r
te o

thi

cal Manual
s
iva

do
r
rp

cum
fo

– Displace the
en
ng

t.
op
yi
clutch disc for‐ Co
wards and back‐
C py
t. rig
gh
wards, and re‐
ht
pyri by
Vo
move excess
co lksw
by
cted agen
grease.
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Complaints Fault description Corrective action

Thumping noise ♦ Idling / primary – Explain the sit‐
when the clutch shaft have sud‐ uation to the cus‐
pedal is in rest posi‐ den vibrations. tomer.
tion. The cogs rattle.
The clutch disc's – Replace the
absorber spring clutch disc.
is broken.

1. Complaints related to clutch and clutch control 9

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

Complaints Fault description Corrective action

Noises when idling ♦ The clutch disc's – Replace the
absorber spring clutch disc.
is broken.

♦ The clutch disc – Install the clutch

was installed disc with the ab‐
without the ab‐ sorber spring.
sorber spring g(vi‐n AG. Volkswagen AG
bration Vwhen wa e does
olks not
idling).
ed by gu
ara
ris nte
tho eo
♦
ss
a The
u
plate's pres‐ – Replace the ra
c
sure plate is clutch plate.

ce
le
un

bent, broken or

pt
an
d

out of balance.
itte

y li
rm

ab
pe

ility
♦ The engine oscil‐ – Check engine
ot

wit
, is n

lates (does not assembly and

h re
operate smooth‐ correct as nec‐
hole

spec
ly). essary.
es, in part or in w

t to the co
♦ Wide misalign‐ – Insert the cen‐
ment of engine/ tralisation pins
transmission (no before installing

rrectness of i
centralisation the transmission.
pins).
l purpos

♦ The intermediate – Assemble the in‐

nform
ercia

plate is touching termediate plate

the flywheel. on the sealing
m

a
com

t
flange and posi‐
ion in

tion it on the lo‐

r
te o

thi

calisation tubes.
s
iva

do
r
rp

cum

1.1 Checking the clutch drive

fo

en
ng

t.
yi Co
op
1. Check the brake fuel level in the reservoir. While doing that,
C py
t. rig
gh
check whether the clutch's hydraulic system has its own chamber!
ht
pyri by
Vo
co lksw
by
2. Check possible external leaks: cted agen
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♦ Master cylinder
♦ Slave cylinder
♦ Tubes/hoses assembly
♦ Supply hose
♦ Connecting points (clip installation and threaded connections),
including in areas that cannot be seen.
External leak symptoms are, for example, fluid traces in or on the
noise muffler under the transmission.
3. Check the route of the tubes/hoses assembly (circuit correctly
fastened). The tubes/hoses assembly cannot be twisted or com‐
pressed.
4. The pedal's return function must not be obstructed by additional
mats or by mats stuffed under it.
5. Depress the clutch pedal. To do this, the pedal must be de‐
pressed and held in five different positions along its entire travel
for approximately 20 seconds (to test different application pres‐
sures in the hydraulic system). Then, a second person checks
whether any fluid is leaking at any of the positions mentioned in
item 2. The first holding position also permits to verify whether the
clutch pedal falls by itself when pressure is maintained.

10 Rep. Gr.30 - Clutch - control system

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008

6. Remove the slave cylinder and check for brake fluid presence
in the bellows.
7. If all tests appear to be OK or if item 6 tests positive, replace
the slave cylinder.

Note

In transmissions in which the slave cylinder and the clutch bearing

form one unit, the transmission must be removed.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Complaints related to clutch and clutch control 11

 Gol 2009 ➤ , Fox 2004 ➤
Troubleshooting, Mechanical Transmission - Edition 04.2008
agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran

34 – Drive, housing
ris tee
tho or
au ac
ss

ce
le
un

pt
1 Complaints related to the selection

an
d
itte

y li
erm
mechanism

ab
ility
ot p

wit
is n
Before carrying out any repairs on the selection mechanism, it is

h re
always necessary to check the customer's complaint and trace

ole,

spec
the problem cause. While doing this, check whether the com‐
urposes, in part or in wh
plaint's cause can in fact be traced to the selection mechanism or

t to the co
to its adjustment. It may be necessary to check whether the com‐
plaint's cause lies in the clutch and in the clutch drive ⇒ page 1 .

rrectne
Repair actions listed in this troubleshooting programme must be
carried out as described in the relevant repair manuals.

ss
Complaints Fault description Corrective action

o
cial p

f inform
There are noises when a forward or ♦ Selection mechanism adjust‐ – Checking and correcting.
mer

reverse gear is selected; the selec‐ ment.

atio
m

tion mechanism gets stuck; it is not

o

n
c

possible to select a gear; the clutch

i
or

n thi
is not working
te

sd
iva

o
r

♦ The selection mechanism is not – Grease the selection mecha‐

p

cum
r
fo

lubricated or is misaligned. nism and replace defective

en
ng

t.
yi
parts.
Co
Cop py
. rig
♦ Defect in the crankshaft needle – Replace the needle bearing and
ht ht
rig by
py
bearing (if fitted). The input shaft lubricate with MoS2 grease.. co Vo
by lksw
is lifted by the crankshaft when‐ cted agen
Prote AG.
ever the clutch is depressed. – Check the centralisation pins,
and replace as necessary.

– Check the input shaft.

♦ Defect in the transmission's syn‐ – Carry out repairs to the trans‐
chronization and/or selection mission.
mechanism.

Complaints Fault description Corrective action

Thumping noise when the clutch ♦ Idling / primary shaft have sud‐ – Explain the situation to the cus‐
pedal is in rest position. den vibrations. The cogs rattle. tomer.
The clutch disc's absorber
spring is broken. – Replace the clutch disc.

04.08

12 Rep. Gr.34 - Drive, housing