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Old July 22nd 05, 12:48 PM
Peter
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"Grahame Rumballe" wrote in message...

> After viewing the scan - It bears little resemblance to the original
> "Workshop Equipment for Local Manufacture" sheets. It has a
> very amateurish look and feel. I wonder if it's a real "local thing"
> i.e. that it's just that dealer/service people who thought it may be
> a could idea to produce a gauge.


It comes from the official VW Germany produced 'Workshop Manual' and does
not appear amateurish on my version. It was not a tool that you could order
from VW, whereas I think the majority (if not all) in the 'Local
Manufacture' manual were also available from the plant (I would have to go
through them all to be sure).

> But back to the gauge, I interpret it as dimension "b" as a scribe
> mark on the plate to line up with the back of the pedal. At that point
> the pushrod is adjusted with no play. Then move pedal back to the
> point on the gauge and adjust the stop plate for pedal position.
> This will give the minimum 5mm freeplay (approx 1mm on the rod).


My version is not scanned and so may be more clear. The diagram does not
state anywhere that the 'cut-off' is a "scribe mark". It also shows the
portion of the template, not including the area outside the 'cut-off', in a
darker (or thicker) line. This clearly indicates that the extra 5mm outside
of the 'cut-off' should not be retained. Along with this diagram (on the
following pages) it states that the "pedal free travel" is to be obtained
first (with the gauge) and then the pushrod should be adjusted to obtain the
play with the master cylinder. Nowhere, in the instructions, does it
explain using the template to measure the pushrod free-play. There is also
an introduction, on these pages, which suggests that the pushrod free-play
is included in the 'pedal free travel'.


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