Interoperability of B3 Passat master/slave clutch with O2J - TDI Engine -General Info - VWDiesel.net The IDI, TDI, and mTDI source.

• Interoperability of B3 Passat master/slave clutch with O2J by dubCanuck1 on 30 Dec, 2006 01:13
• Hi all,
  
  I've FINALLY gotten around to reopening the TDI project. I'm just doing a tally of parts I need and don't need. I've got a Clutch master and slave cylinder from a B3 Passat. It's different from the slave cylinder that I've got on the 02J (EBJ code for TDI).
  
  I pulled out the one that came with the tranny, and apart from a dust shield, they look pretty much identical in function (you press the pedal, it extends). I'm just being very cautious right now, so wanted to solicit some advice from others who may have used this combo (or a Corrado one, which is the same).
  
  I don't want to have to buy the hole pipe/master setup from the dealer as it would be pricey, so help a fella out....
  
  Thanks.
• #1 by RabbitGTDguy on 30 Dec, 2006 08:34
• where there is a will...there is a way. Cost seems to come into play there, but this shouldn't be too bad...
  
  
  I had a corrado that was automatic, that I swapped to standard trans... I had all passat parts and it worked flawlessly and was very smooth...did it in a weekend by myself at home. Short of a bruise on my chest from the old auto slush box  coming down with no one to help, I was good to go. oh..and a broken shift box cable, but we took care of that...
  
  Anyways...truth be told, the b3 assembly works the best with the b3/02a style parts and the o2j with the 02j parts, etc. Isn't the placment different on 02j's slave in the first place? Design and function will be the same, but you'd at the very least need to get the approriate lines made for it to reach from its location to the clutch master (combination metal/rubber lines), need to check for the total stroke of the 02j slave cylinder vs. that of the 02a one (don't want it too short to actutate the clutch finger, could eventually blow seals on the slave, or just not actutate the finger completely at all, or to long...), etc. The lines length in your case is probably the biggest problem.
   Some things to consider. I'm sure it could be done.
  
  Seems like the slave has always been the weak part in the VW system... even with the 02j MKIV transmssions, etc. people still seem to go through slaves alot! If I had my way, and could find all the parts....MKIII TDI tranny, or b4 tranny with the eurovans cable actutated clutch...
  
  In simplier terms...what would I do? I'd try and run what you have... the b3 master setup but with the correct slave cylinder for the 02j tranny. The 02a one if I remember is slightly longer...the 02j one...more stubby. From there, its going to be fitting the correct metal/ubber line run from the master to the slave and from there, everything you'd think should work fine. I think attempting to use the b3 one would cause interference problems possibly because of its length...again, don't quote me... but its an idea...   a hydraulics shop could possibly make the lines...or you could find the line on a parted mkiv possibly. I doubt there is a huge different in the length from the mc on the MKIV  to that of it on the B3, corrado, etc. seems to always be some extra room to play with...
  Don't know if that helps...or is clear, let me know if more detail is needed...
  
  Joe
• #2 by dubCanuck1 on 30 Dec, 2006 08:51
• Thanks for the reply. I've got the complete master/slave/hose setup for the B3. Since the whole thing's going into a MKII, which is essentially the same as the Passat, distance isn't an issue.
  
  The issue is that, to use the 02J slave, I'd have to buy the 02J Master and the hose to go with it because they switched from threaded brass connections (similar to brake connections), to a locking clip sort of mechanism, which I'm currently getting pricing on.
  
  Here's a pic of the pieces I got from the B3. I made sure to get the whole shebang, including the reservoir, which isn't pictured in there.
  
  
• #3 by RabbitGTDguy on 30 Dec, 2006 09:27
• I see...
  
  Did you check the mounting of the 02a one vs. the o2j slave? are they the same...?  if so...it'll mount...so no biggy there...
  
  Did you check clearance for the o2a one vs. the 02j one? If it'll clear without inteferring...then you have that down...
  
  Will the lines reach...sounds like it will from what you have said...
  
  So the biggest thing left would be checking the 02a slave vs. the 02j slave for operation, full stroke, etc. to make sure the one doesn't "reach" terribly longer or shorter, etc. so you reduce the chance of blowing up the slave from excessive pressure, or no clutch operation due to being too short. Guess this is the biggest thing that you need to check ... if all of it is similar...you could possibly use the b3 slave , and thus the entire b3 setup vs. having to go to the o2j stuff...
  
  Joe
• #4 by dubCanuck1 on 30 Dec, 2006 09:39
• Thanks Joe. I had planned to extensively test the setup on the 02A, including throw, before I even drove the car. I believe G60ing on the Tex used his Corrado SLC TDI hydro setup on his 02J, so am waiting for feedback there as well.
  
  I'm just heading out to the garage to confirm the fit up, but I'm pretty sure it's the same.
• #5 by RabbitGTDguy on 30 Dec, 2006 09:46
• I believe your right as well on g60ings setup...
  
  Good luck... let us know how it goes...
  
  Joe
• #6 by dubCanuck1 on 30 Dec, 2006 09:55
• Just checked and the slave for the 02A bolts in just fine. It has about the same tension as the 02J one did. I priced out the master and pipe for the 02J and it came out to just over $300 CDN for the two. That's enough to make me do some more research.
• #7 by RabbitGTDguy on 30 Dec, 2006 10:06
• ouch...  you could always check worldimpex for what you need by entering the p/n, etc. but if the 02a stuff will work...i'd go with that. Make sure you check your used 02a b3 slave first...when I did the corrado swap, the slave was good for about a month or two and then I ended up replacing it. Probably will have to do the one in the b3 here before spring I imagine too... they don't like to sit...
  
  Joe
• #8 by dubCanuck1 on 30 Dec, 2006 12:13
• Yeah. I'm not too worried if it goes. I just don't want to spend any more money than I need to get this thing running. After all the changes to the project, I'm at or over $10000 invested (at least $2000 in parts that fit into a napsack). So if some parts wear out a little down the road, I'm OK with that as a "maintenance" fee.
• #9 by dubCanuck1 on 31 Dec, 2006 13:31
• Hey Joe,
  
  It bolted up just fine. Here's the pics. I compressed the finger on both and they have the same throw, plus it seems that there's no difference. A guy on the Tex said that when you ask for the replacement for the 02A, they give you the same piece from the 02J. I'm going to take that as a good sign.
  
  02J slave
  
  02A slave
  
• #10 by RabbitGTDguy on 31 Dec, 2006 13:54
• Very interesting! I'll keep that in mind if/when I do the 02a/j swap on the MK1 *it could be immenent* and when I need to buy a replacement for the B3! Glad to see it all worked out! How close to completion are you?
  
  Happy New Year by the way!
  
  Joe
• #11 by dubCanuck1 on 31 Dec, 2006 14:00
• I'm just getting back into the swing of the project. I originally planned for the end of 2006, but that's turning into more like end of Q1 2007 for the car to be running and on the road again (looking like a$$, but running), due to parts, time, and money restrictions.
  
  I just put an order in for what I think is the last of the parts I needed to complete the project.
  
  I've got a ton of body work lined up for it next winter, so I guess technically, it'll never be done...
• #12 by RabbitGTDguy on 31 Dec, 2006 14:12
• I know and share that same boat with you. Costs and time quickly add up when doing something right and even then its never truly done. I was lucky to complete my engine this spring, get it in and running...but I still have plenty of ideas, goals and upgrades planned for the car. Mainly power and general upgrades this winter to further the potential of the car...but also bodywork and paint somewhere down the road. Was hoping for this winter...but like you, it'll probably be next year. Guess I'll be going scary "rat stylz" for spring/summer of 07...but then again, that was fun this year by the reaction I got on the highways
  
  Joe
• #13 by dubCanuck1 on 01 Jan, 2007 03:07
• Got some love from the vortex guys (plus I'm wickedly drunk tonight...happy new year's).
  
  http://forums.vwvortex.com/zerothread?id=3000291
  
  Looks like no issues with 02A/02J compatibility.
• #14 by RabbitGTDguy on 01 Jan, 2007 08:16
• :lol:  Every now and then they do come through
  
  Happy New Years!