MK5 2.0 GT TDI 140 (BKD) Brand new slave cylinder leaking?!

[FrenchToGerman]

Hi all,

I changed the clutch and flywheel on my golf over the weekend, I took my time with it and torqued everything up to spec, got the gearbox back on the car and proceeded to bleed the clutch.. this is when it all wen't wrong! I had been trying to bleed the clutch for a good few hours and the pedal wasn't getting any better and would just stick to the floor every time after bleeding even after getting what i thought was all of the air out of the system.. carried on a bit longer until i noticed it was literally peeing brake fluid out of the bell housing.

I have now taken the gearbox back off to find the slave cylinder leaking right out of the seals, Is this just a case of a faulty part or could I have done something wrong? I have new parts on the way to fit but i'm worried its going to happen again! its leaked allover the clutch disc too so that's gonna need replacing, luckily the place I got it from have accepted responsibility and are sending new parts free of charge.

Any ideas what would cause this? I don't think it was actually leaking to start with i'm pretty sure it started to leak after the constant bleeding so i'm confused what has actually gone wrong.

[bill.wj.wilson]

Mate of mine has a garage was making up new brake lines and fitting the flexi pipes supplied by the customer. Same scenario as you brake fluid everywhere the crimp on one pipe had never been closed, straight from the manufacturer in a sealed bag, quality control doesn't exist anymore.

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[FrenchToGerman]

Nightmare, hope the next one is ok don't fancy taking the gearbox off for a third time!

[Crasher]

quality control doesn't exist anymore

That is because the vast majority of people buying parts are chasing price not quality and so the suppliers give people what they want, we have a lot of trouble getting hold of premium quality parts, having to fight our way though virtual piles of Chinese crap.

[bill.wj.wilson]

I agree but I'm fed up with manufacturers parts being crap as well, but as you say it's made to a price not a standard, I bought a VW in good faith, only to find it had a cheat programme and the update sucks as well causing all kinds of issues, seems now there's more appearing every day from different manufacturers, the latest Daimler and BMW. What ever happened to pride in your product.

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[Crasher]

The emissions cheat thing was blown out of all logical and sensible proportion and the "fix" did more harm than good as VAG were harassed into a quick fix that didn't work but it shut the press up and now slowly proper updates are coming out which solve the problems, I did the latest update on a Golf 6 TDI last week and it made the idle so much smoother and no excessive combustion noise. I don't tend to have any problems with genuine dealer parts, every now and again TPS will send me a new box with an old part in it that has been returned by some slimball of a customer for credit and THEIR quality check misses it (i.e. a non existent check) and then they send the bit out to someone else. I dread getting a problem with a genuine part as the TPS terms dictate that the warranty has to be dealt with by the marque appropriate dealer and they get grumpy as they did not sell you the part in the first place.

[bill.wj.wilson]

Rushed or not I was sent DVSA headed paperwork yet when my car went **** up I'd a major issue getting any help from VAG, suddenly it was a voluntary action.
There's over 7000 folk on the VW forum having trouble nevermind Seat, Skoda, Audi, a corporation doesn't give a monkeys about Joe public until they get caught.
There's bound to be more coming along soon as well.

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[FrenchToGerman]

New clutch disc and slave cylinder going back on today.. just wondering can anyone confirm the torque specs for the clutch pressure plate? just want to make sure everything is right, I have found 20NM on research..

thanks

[Crasher]

If the issue had been just left alone and the cars not messed with, it would have been OK. There are far more cars out there with illegal removed DPF's and the so called "cheat" cars were massively cleaner than the cars they replaced even with the cheat, the whole problem is the fault of the California Air Resources Board placing unrealistic demands on the car manufactures. If they had followed suit with the EU (who's specs were still tight) this would never have happened. On the subject of large corporations, give me an example of any in the worlds top 100 companies who APPEAR to give a damn about the public, look at Toyota with the Takarta air bag scandal where dozens of people died before they lifted a finger? I think they do care but how does a large corporation employing tens of thousands show this like a small business can, well has to!

M6 bolt, 13 Nm, M7 bolt, 20 Nm

[FrenchToGerman]

Does anyone know if there are two types of clutch kit for the 140bhp BKD TDI engine? the new clutch kit looks alot different to the old one and i'm a bit concerned this may be the issue as the old clutch looked like the clutch "fingers" seemed to stick out further than the new one and i'm thinking its not making proper contact with the slave cylinder as when i dismantled it the slave cylinder looked asif it has tried to force itself apart due to the pressure inside it if that makes sense to anyone, kinda hard to explain..

[Crasher]

There were Sachs and LUK systems from new, so what make is it? The Sachs and LUK do look different and you are replacing the DMF aren't you?

[FrenchToGerman]

There were Sachs and LUK systems from new, so what make is it? The Sachs and LUK do look different and you are replacing the DMF aren't you?

The new kit ive installed is a Sachs which includes new DMF, clutch kit and slave cylinder. The old kit was a LUK Kit but the supplier told me both kits will fit my car so i wen't ahead and fitted it.

Now ive just fitted it all for the second time, bled the clutch and there is zero air coming out but still it will not go into gear? really getting sick of this now not had a car for a week and I feel like they've sent me the wrong clutch kit and this is the issue. The supplier is adamant that both kits fit my car, well yes they both bolt on but the car wasn't having any issue getting into gear before i installed this other clutch kit the whole reason i swapped it was due to the DMF being bad.

[Crasher]

Private message me your reg number and the Sachs kit number. Have you bled it by foot or pressure bleeder?

[FrenchToGerman]

Private message me your reg number and the Sachs kit number. Have you bled it by foot or pressure bleeder?

I've tried to bleed it both ways pressure and by foot, i can't seem to get anymore air out of it so i really don't know where to go from here other than ripping it back apart again. ill send them over now.

Also this is a link to the same clutch kit https://www.cartech-one.co.uk/en/product/85527-clutch-kit/v-17280

[Crasher]

Using that Sachs kit number 2290 601 009 in Tec Doc it comes up as the right kit and it is a slightly increased duty X Tend unit BUT it does not give me the part numbers of the parts in the box

http://toc.tecdoc.net/cis/documents/DEhEce-wNxxBJYgLU/1538012/0

Using the ETKA FI Suggestion VAG numbers using your VIN for a factory fitted Sachs system and converting these to Sachs numbers I get

Flywheel 03G 105 266 BN is Sachs 2294 000 113

Clutch kit 03G 141 015 L is Sachs 3000 970 004

Release bearing 0A5 141 671 F is Sachs 3182 654 150

Can you check these numbers against the boxes the parts came in?

[FrenchToGerman]

Using that Sachs kit number 2290 601 009 in Tec Doc it comes up as the right kit and it is a slightly increased duty X Tend unit BUT it does not give me the part numbers of the parts in the box

Apache Tomcat/7.0.52 - Error report (http://toc.tecdoc.net/cis/documents/DEhEce-wNxxBJYgLU/1538012/0)

Using the ETKA FI Suggestion VAG numbers using your VIN for a factory fitted Sachs system and converting these to Sachs numbers I get

Flywheel 03G 105 266 BN is Sachs 2294 000 113

Clutch kit 03G 141 015 L is Sachs 3000 970 004

Release bearing 0A5 141 671 F is Sachs 3182 654 150

Can you check these numbers against the boxes the parts came in?

Hi, thanks for the reply, its all sorted now.. i decided to take the gearbox back off to find that i had put the clutch disc in backwards as I was rushing to get it back together the second time, Ah well. lesson learnt always double check your work before you throw the gearbox back on lol!

[Crasher]

It would help if Sachs put the English translation of Getribe Seite “gearbox side” on the friction plate as well.

[sacha35]

Been watching this thread with interest and glad you got it sorted in the end. That was a very good price for a complete clutch kit including duel mass flywheel what millage did the old one give out at? or was there other factors.
maybe Crasher can throw some light on what make is better Sachs or Lux or are they much the same.
Anyway all the best and hope it give you many years of trouble free motoring.

[Crasher]

Either, there is nothing to choose between them.

[FrenchToGerman]

Hi, I replaced the whole lot eventually at 93k but the flywheel has been on the way out since about 60k but it got to the point where it was rattling a lot and sounded awful, at first it wasn’t bad just giving the odd shake now and then. The clutch was actually still ok and had quite a bit of life left by the look of it but may aswell change the lot whilst you’re in there.

[sacha35]

Hi, I replaced the whole lot eventually at 93k but the flywheel has been on the way out since about 60k but it got to the point where it was rattling a lot and sounded awful, at first it wasn’t bad just giving the odd shake now and then. The clutch was actually still ok and had quite a bit of life left by the look of it but may aswell change the lot whilst you’re in there.
Did you use the clamping device special tool for the
clutch pressure plate to dual mass flywheel or did you get someone to do this for you as I can see the tool does is quite expensive and would add considerable price to the job especially if its a one off.

Thanks again for the info guys its very helpful.

[FrenchToGerman]

Hi, I’m unsure what tool you mean? I didn’t need any special tools to fit the clutch other than a clutch alignment tool which cost me £13

[sacha35]

Hi, I’m unsure what tool you mean? I didn’t need any special tools to fit the clutch other than a clutch alignment tool which cost me £13


I thought it need a special tool as it could cause damage to the dual mass flywheel when bolting up and could twist and be damaged without it. https://www.youtube.com/watch?v=Tp5KeAQntGM hope I am wrong as these are not cheep maybe crasher could throw some light on the subject ,here is a link to the tool I am talking about. LuK SAC Special Tool | REPXPERT Site US (https://www.repxpert.us/en/work/productcatalog/product_ds3411)

I have an Audi so maybe a bit different but they both have the
dual mass flywheel
, here is the vid for Audi which shows same sort of tool being used. Schimbul modulului de ambreiaj LuK pentru Audi b8 2 0tdi - YouTube (https://www.youtube.com/watch?v=inAfFGIrxT4)

[FrenchToGerman]

It does say in the description that the tool is encouraged but not necessary. In my opinion you should be fine as long as you do up the pressure plate bolts in stages ensuring it clamps down even, there’s a few YouTube vids of people changing out the clutch and dmf and I’ve not seen anyone use this tool yet

[sacha35]

It does say in the description that the tool is encouraged but not necessary. In my opinion you should be fine as long as you do up the pressure plate bolts in stages ensuring it clamps down even, there’s a few YouTube vids of people changing out the clutch and dmf and I’ve not seen anyone use this tool yet

Yes just see that bit, was a little worried at having to purchase such an expensive tool for a one off job. Amazed that the kits are not being sold already assembled as with the Audi anyway it looks like the assembly is in the gearbox and blotted to the flywheel ring gear engine side shown in this vid.

Замена �цеплени� �уди �4 / Clutch replacement Audi A4 - LUK - YouTube (https://www.youtube.com/watch?v=Rarwlb7pUpI)

Thanks anyway.