Repairing clutch release mechanism

Make

Volkswagen

Model

Polo Mk5

Section

5-speed manual gearbox 02R › Clutch, control › Repairing clutch release mechanism

Power transmissionRepairing clutch release mechanism

Repairing clutch release mechanism Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

1 -

Gearbox

2 -	Ball stud, 25 Nm

q	To remove and install, remove gearbox

q	Remove old grease from contact surface of clutch release lever

q	Lubricate with grease -G 000 100-

3 -	Input shaft seal

q	To remove and install, remove gearbox

q	Renewing → Item

4 -	Guide sleeve

q	To remove and install, remove gearbox

q	With vulcanised or bonded O-ring

q	If O-ring is damaged or has come loose, renew guide sleeve and O-ring together

5 -	Retaining spring

q	To remove and install, remove gearbox

q	Secure to clutch release lever

6 -	Socket head bolt, 20 Nm

7 -	Clutch release lever

q	To remove and install, remove gearbox

q	Remove and install together with release bearing → Fig. and → Fig.

q	Remove old grease

8 -	Release bearing

q	To remove and install, remove gearbox

q	Do not wash out bearing; wipe only

q	Renew noisy bearings

9 -	Flange bolt, 20 Nm

10 -	Slave cylinder

q	Removing and installing → Chapter

11 -

Plunger

12 -	Assembly bolt

q	Secures clutch release lever when gearbox is installed

q	Remove after gearbox has been installed.

  Note

If assembly bolt → Item is not available, an M 8 x 35 bolt can be used.

Removing and installing release lever together with release bearing –  Unhook spring -arrow 1-. –  Pull off release lever -arrow 2- and release bearing. Install in reverse order of removal.

Removing and installing release bearing –  Press together retaining hooks -arrows- on back of clutch release lever and remove release bearing -A- from clutch release lever. –  To install, press release bearing -A- into clutch release lever until retaining hooks -arrows- engage.

04 Transmission