B7 Passat Clutch/Flywheel replacement failed concentric slave cylinder
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- Опубликовано: 22 июл 2024
- In this video I show how you can change the duel mass flywheel, clutch and slave cylinder on a Volkswagen Passat B7 (MK7) 2.0 TDI with the CFFB engine. This is a long one so grab a cup of tea and enjoy.
If you found this video entertaining or informative then consider buying me a coffee (or a cup of tea in my case 😁)
buymeacoffee.com/cavalier_steve
Music:
Into: Deep State-Vans In Japan
Track 1: Abracadabra-Silent Partner
Track 2: Night Runner-Audionautix audionautix.com/ Music by Audionautix.com
Track 3: Accidents Will Happen-Silent Partner
Track 4: That One Bar Scene-RKVC
Track 5: Eyes on You (Sting)-Network 415
Track 6: Overdrive-Corbyn Kites
Track 7: Chilltronic-RKVC
Track 8: Rich in the 80s-DivKid
00:00 Intro
01:50 Symptoms
05:00 Battery Tray/Air box removal
12:22 Undertray Removal
14:08 Removing Electrical Connectors
17:15 Starter Motor Removal
21:41 Gear Linkage Removal
26:31 Bottom Gearbox Mount removal
27:00 Drive Shaft Removal
32:36 Gearbox Bolts
37:00 Top Gearbox Mount Removal
38:26 Wrestling The Gearbox Out
41:10 Drain Gearbox Oil and Drives Shaft Coupling removal
42:19 Gearbox Out
42:51 Day 2 Bellhousing Cleanup
43:27 A Look At The New Clutch Kit
44:20 Remove And Install The New Slave Cylinder
47:00 Pressure & Friction Plate Removal
48:03 Flywheel Removal
49:24 Comparing Friction Plate Thickness
50:47 Flywheel Install
55:16 Clutch alignment tool
57:33 Pressure Plate Install
01:01:10 Wrestling The Gearbox In
01:02:42 Gearbox Aligned
01:04:14 Day 3
01:06:20 Reinstalling The Gearbox Box Bolts
01:10:54 Bottom Gearbox Mount Install
01:14:34 Drive shafts Install
01:15:18 Hub Bolt Install
01:16:54 Starter Motor Cables Install
01:17:50 Top Gearbox Mount Install
01:18:52 Bleeding The Slave Cylinder
01:21:32 Gear Linkage Install (Timelaps)
01:23:57 Battery Tray & Airbox Install
01:26:35 Quick Test
01:28:00 Refill Geabox Oil
01:29:42 Final Thoughts
01:30:13 Outro 
Авто/Мото
Just sent my B7 off to my mechanic to replace the DMF. Texted him my sympathies after watching this. Great video man ! Well done
Thank you for your kind words, I’m glad the video helped you diagnose the issue, I hope that the work doesn’t cost you to much money. Hopefully you will be back on the road soon. Cheers.
Hi Steve, thanks for putting in the time and effort of doing this video. I had a failed slave cylinder on my passat and managed to change it and the clutch with help from your video. I had a similar issue wrestling the gearbox back in, easily the hardest part of the job getting it back in. Thanks
Wow that’s brilliant, well done 👍 yes totally agree the gearbox was a pain to get in, I cut some of the time laps out so it wasn’t too boring. Definitely worth doing the clutch it’s expensive but at least you know it would last the same as your other one did. Thanks for the feedback I love reading success stories like this, well done 👏 👍
This is the best video i've seen of a MK6/MK7 tranny removal and clutch replacement. Really great video!
Oh wow, thank you very much, it’s always nice to hear feedback like this. I hope your project goes ok.
All the best.
Steve.
@@Cavalier_Steve yeah man. I have to replace my slave cylinder because it is leaking. Not looking forward to it but glad I have this video to follow.
@@DylanGoebel That’s Awesome, it’s not a bad job to do, it’s easier with a buddy helping you out but you can do it yourself, it’s the weight and size of the gearbox that’s a pain, other than that it’s just nuts and bolts. Cheers.
@@Cavalier_Steve that's what I'm seeing. I'm 115lb soaking wet and was reading forums where the people were saying to just drop the trans on yourself then roll it off lol. I'll use some jacks like you did.
I tried to use that method, but it’s way to heavy for me to do that, you need so much strength to hold the gearbox up and try and get a bolt in, honestly it’s not worth it. I would definitely go with the 2 jacks, it’s a pain but you can get it in… eventually.
Please let me know how you get on, I would be most interested.
Great job Steve! I know how much effort you put into these videos and you have done stellar on that side of things whilst doing such a complicated job on the car.
Thanks Sammy!!! It was a lot of work and filming made the process longer, but it was definitely worth it as I don’t think the video come out to bad in the end. Especially as there was over 9 hours worth of footage 😮
Can you do mine now haha😂 thanks for the video!
😂Yeah don’t want to do that in a hurry! Good luck with yours though! Are you doing it yourself??
Loved the video I've my daughters Skoda Superb 4 x 4 to do not the same car I know but similar !!!
Hi Anthony, glad you liked the video and I hope that it helps you with your daughters car, the 2 cars I would think are very similar so I bet it would be almost the same, the only difference being the prop shaft for the 4x4 that and the gearbox on your daughters car will be much heavier than what mine was and that was heavy! So be aware of that when you get it out. Other than that it's not to bad of a job just awkward to do. This took me 3 days including filming and going steady. Good luck with your project and I hope you don't get to many snags. Cheers.
Great video, i think you are a nutcase/genius - imagine being able to do all that and on a drive! I think twice about changing a tyre
that is probably a £2000 job at VW
I’m firmly in the nutcase category 😂 yes I think your right about it being £2000 definitely worth doing it myself! I have repaired a slow puncture on a tyre an (internal patch) it was on a steel wheel I wouldn’t do an alloy wheel though as the tools I use will scratch them. Thanks Alan!
Hi Steve, my first thought watching this was rather you than me😂 I think you did a fantastic job on the Passat mate as that was quite a big job to do in the drive using axle stands but you didn't seem to have many problems apart from fitting the gearbox back onto the engine but lining the splines can be a right pain🙄
The last time I did a clutch change was back in the 80's on my Mk3 Cortina, removing a big gearbox just using ramps was horrendous it would have been easier to remove the engine🤦♂🫣
Anyway Steve a great video, very well made and edited👏🙏👍
Hi John you managed to finish the video then 😂 it was a big job I quite enjoyed doing it in a way but definitely don’t fancy doing it again anytime soon! It was fairly straightforward and as you say working on the floor where you don’t really have Mitch strength in your arms and it was a pain to get aligned up, I think the issue was the input shaft wasn’t aligned with the clutch friction plate no biggie once I worked out that you can turn the engine over using a socket 🤦♂️ it was knackering. Sounds like you done a fair amount of work on your cortina back in the day mate! Fair play to you! Thanks for sticking with it and I hope you enjoyed it mate. Cheers.
Yes mate I really enjoyed watching it and I got through it in two sittings😎 as it bought back fond memories of when I used to do all my own repairs, it's always a PITA getting the input shaft lined up when refitting the box but you did a fabulous job on it mate.
I had a total of 4 Cortina's back in the 80's, I've probably told you before that one of them had a twisted subframe (clip) so I had to totally strip the entire front of the car down to it's bare shell, I bought a second hand clip from a breakers then replaced all the joints, bushes and steering rack and refitted it, it took a few days to refurbish the clip due to ordering parts but once it was rebuilt I got the whole job done over a long weekend including engine out and new clutch, absolutely loved it mate but couldn't do it now👍
Hi Steve, great video, mate. I'd be quite disappointed as well with a failure at 61,400 miles, quite a job, I'm sure if you weren't on such short hours a day and a half would have got you there 😉 😂.
Seems like it stayed dry, but cold which is better than the wet, I guess you used to watch the fast show as a "nice" cropped up 😂.
Impact wrenches are brilliant for difficult to remove stuff or bits you normally need to lock. It's good to see it in action
Great camera work, I'm sure most will appreciate the amount of effort that goes into just filming it all, let alone have to do all the work as well.
I think all gear oil has the pull out spout. Certainly, all the ones I've used have.
Thanks for all the effort you go to in making the videos mate, good to watch, I would have done the same , replacing the clutch even though it wasn't the problem. Cheers Steve
Hi Pete, yes I was disappointed but I forget how old the car is it will be 10 years old next year, but considering how I drive I’m still disappointed really, I’ve not put any break pads on it yet! Yeah I probably would have got it done in the same time if I haven’t filmed it but after doing 6 hours I was knackered filming I find takes it out of me because your thinking of the job and what your saying to camera as you know. Plus I needed to make a cup of tea in-between times 😁
I didn’t even see the lid of the oil top 🤦♂️ I’m pleased to hear from someone like yourself that you would have also changed the clutch and flywheel, we both know after messing with it and our luck it would have failed a month after I put it back together. I recorded this in January so days was short and I was lucky with the weather for a change, it was a bit cold but once you was working you soon warmed up again.
Thanks for the feedback re the camera etc. it’s hard to get the angle right and making sure the subject your talking about is actually in the picture. There’s plenty of bits I had to do again.
I’m glad you enjoyed it though mate! Even though it was a marathon. I’ve got a few shorter ones coming up but who knows until I record them… we will see. Cheers.
Mine also failed, 63k miles, 7 year old. £660 to fix… mostly labour, the part was only a few quid. Absolute sickener. Great vid though.
Wow I think the slave cylinder is only about £20, I would have got away with just changing mine but I didn’t know until I got everything out, at least I can guarantee that it would last until at least 120K hopefull… 😂 thanks for the comment. It’s nice to hear feedback on what people thought of my video. Thanks. 👍
@@Cavalier_Steve yea £20 seems about right, poor design though in general, fails across all the VAG range. The older exterior slave of the 5 speed was much more sufficient, and more reliable… many lasting the life of the car. The good old days…
How do I tell if it’s the concentric or master cylinder slave? I have the same issue as you. The pedal is stuck most of the way down. Won’t engage any gears.
Hello there.
The first thing I would try is bleeding the slave cylinder, the peddle won’t return as it relies on the back pressure from the pressure plate against the slave cylinder to return the peddle if that makes sense, the best thing to do is, pull the clutch pedal up then open the bleed nipple, then push the pedal back down you should get fluid squirt out as the pedal is pushed, do this a few times until the fluid runs clear and free of air bubbles (put some clear tubing on the nipple to aid you see how much air is left in, your looking for a full tube with no air bubbles in the fluid, do the nipple back up. If you get fluid pumping through it’s likely that the master is ok, another test you can do is crimp off the rubber line to the slave cylinder try pushing the clutch pedal again, if it locks up or is harder to push it’s likely that your master is ok as the fluid flow would be restricted to the slave or totally blocked off, either way it shows that the master is good as you may not be able to fully crimp the hose, if it’s still easy to push and you can’t get fluid through via pumping, then the master is at fault.
(It’s likely that you will get a lot of black looking fluid come throughout if your able to push fluid out of the system ensure you allow this to clear by pumping the old fluid out and topping the master up as you go (flushing the clutch hydraulic’s out)
If your not getting fluid from the master, ensure the break fluid is topped up as the fluid take off is higher than the actual break fluid master cylinder take off, this is a safety feature as it ensures if the system was to leak the clutch will be the first to fail over your breaks. Hope that makes sense for you.
If your unsure of anything then please reply back and I will try and explain it better for you. Let me know how you get on.
Good luck.
Steve.
@@Cavalier_Steve Tried bleeding the clutch and some fluid is pushing out but not much. A lot of bubbles. Plenty of fluid in the chamber so I’m guessing it’s the master cylinder slave. Also clamped the line and can’t get any pressure.
@gavinrees5854 Does sound like your master cylinder is at fault fingers crossed 🤞
Hi steve! Great video👍 i was just wondering if i have to bleed the slave cylinder before mounting the gearbox back in?
Hi! And thanks 😊 it would be nice if you could but sadly I don’t think you can as the line from the master cylinder is quite ridged, even if you put fluid into the slave there will be air in the feed pipe from the master, don’t forget when you open the line up the fluid from the break fluid reservoir all the fluid would gravitate out, saying that you could prevent this by simply keeping the clutch pedal pushed down, bleeding the clutch system isn’t that difficult anyway, I don’t think it’s worth the hassle. Good luck with your project, let me know how you get on.
@@Cavalier_Steve thank you steve😃👍 clutch will arrive next week👍
@@oplbaton7472 Brilliant! Was the clutch slipping on yours or did something else fail? It’s not a bad job the hardest part is getting the box in and out I’m sure it would be so much easier with a 2nd person to help.
@@Cavalier_Steve i noticed one morning when i was going to work my clutch was stuck at the floor and i couldn't put it in gear, i noticed the master cylinder was leaking a little when we pumped the clutch so we tried to change it, the car laste for another 2 months until i noticed my clutch pedal started getting really soft and a week later it got stuck again, so i took my transmission out and saw the leak in the slave cylinder. I'm not sure how many km the clutch have done but the previous owner did 90 000km with the car and me 6000km so far, the car has a total of 270k km so far :)
@@oplbaton7472 They are good mileage munchers, mine didn’t need replacing the friction plate still had loads of meat left on it, I considered selling mine 😮 as I said in the video you never know what you’re going to find at least I can guarantee the setup will last until 120K miles at least 😁 if the salve failed again i probably wouldn’t bother as the clutch setup itself would have easily done 120K+
samething Happend to mine,its started by going soft i kept driving than i had to pull back the pedal with my foot,afta a little while the pedal was stuck to the floor ...Break fluid was dirty but no sign of leake on the master cylinder and no sign of leak on the Box,any suggestion on what could be the problem Steve?
its a Golf 6 gti
Hi Senzom, it sounds like you're experiencing the same issue I had with mine, the slave cylinder could be leaking internally, this doesn't leak fluid out as you may expect and you probably won't get any fluid loss, I think the seal breaks down and causes the fluid to leak past the seal insted of pushing it out as the clutch peddle realises on the pressure plate spring to push the slave back this internally pushes the fluid back up the line and into the master cylinder and this is what returns the clutch peddle (I hope that makes sence) I also had black fluid especially when I took out the old slave cylinder, this could be the rubber that has broken down or more likely is that the break fluid is old and as it's hygroscopic it has the ability to absorb moisture and this moisture turns the fluid dark and eventually black. You could try bleeding the slave cylinder but it's highly likely that your slave or master has failed, if you are able to bleed fluid out of the slave cylinder then chances are your master cylinder is good. I hope this all makes sense foe you, if you have any further questions then please come back to me. All the best. Steve.
@@Cavalier_Steve thanks Steve...i tried taking the pipe out the bleeder nipple the one that goes to the slave cylinder, i than pumped it with some air hoping the pedal with get pressure nd get stiff but it ddnt,its was still goin down to the floor,i dont know if i was doing it the right way if i dd that
@senzom4484 no worries, if I have read your reply right it sounds like you removed the pipe from the slave cylinder, you won’t bleed the cylinder this way (not completely anyway) I would put a bit of clear pipe on the bleed nipple you would be able to see the air bubbles. Any air in the system would compress it wont transfer the fluid properly. Usually you don’t get air in the system for no reason I still suspect your slave cylinder.
Thanks a Lot Steve i took out the Box nd find out its was the slave it was leaking internal...i also checked my clutch nd find out the plate was almost gone ,i already bhought a clutch kit nd the Slave
Top job Steve, I enjoyed that. Not sure I'd tackle it though, it would take me even longer. I wonder what the labour charge would have been at VW 🫣.
Thanks Paul, I’m not sure how much it would have been, I wouldn’t mind betting that it would be around £1500. Cheers.