Repairing clutch release mechanism

Make

Volkswagen

Model

Polo Mk5

Section

5-speed manual gearbox 02T › 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 -	Release bearing

q	To remove and install, remove gearbox

q	Remove and install together with clutch release lever → Item and guide sleeve → Item → Fig. to → Fig.

q	Do not wash out bearing; wipe only

q	Renew noisy bearings

2 -	Bolt, 5 Nm + turn 90° further

q	Always renew

3 -	Clutch release lever

q	To remove and install, remove gearbox

q	Remove and install together with release bearing → Item and guide sleeve → Item → Fig. to → Fig.

q	Remove old grease

4 -	Retaining spring

q	To remove and install, remove gearbox

q	Secure to clutch release lever

5 -	Guide sleeve

q	To remove and install, remove gearbox

q	Remove and install together with release bearing → Item and clutch release lever → Item → Fig. to → Fig.

6 -	Input shaft seal

q	To remove and install, remove gearbox

q	Renewing → Item

7 -	Ball stud, 20 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-

8 -

Gearbox

9 -	Hexagon bolt, 20 Nm

10 -

Bracket

q	For pipe/hose line

q	Only in Polo 2002 ►

q	Determine according to → Electronic parts catalogue (ETKA).

11 -	Slave cylinder

q	Removing and installing → Chapter

Removing and installing clutch release lever with release bearing and guide sleeve –  Remove bolts -arrows-. –  Pull clutch release lever with release bearing and guide sleeve off input shaft and ball stud. Install in reverse order of removal.

Removing and installing guide sleeve –  Push guide sleeve -3- upwards out of release bearing -2-. –  Turn guide sleeve -3- about 90° in direction of arrow relative to release bearing -2- until locking lugs of guide sleeve align with grooves -4- of release bearing. –  Pull guide sleeve out of release bearing in this position. Install in reverse order of removal.

Removing and installing release bearing –  Press together locking lugs -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 lugs -arrows- engage.

04 Transmission