Polo Mk5
| Repairing gearbox housing and clutch housing |
| Special tools and workshop equipment required |
| t | Press tool -VW 408 A- |
| t | Spacer sleeve -VW 472/2- |
| t | Centring mandrel -12-551- |
| t | Thrust piece -30-555- |
| t | Spindle from assembly tool -3066- |
| t | Thrust piece -3124- |
| t | Gearbox support -3221- (modifying → Chapter) |
| t | Multi-point bit -3357- |
| t | Thrust piece -T40008- |
| t | Torque wrench -V.A.G 1331- |
| t | -2-Puller -Kukko 18/1- |
| t | -3-Splitter -Kukko 17/1- |
| 1 - | Clutch housing |
| q | Made of either aluminium or magnesium. |
| q | Allocation → Electronic parts catalogue (ETKA) |
| q | If renewed, adjust differential → Chapter |
| 2 - | Input shaft seal |
| q | Lever out with a screwdriver |
| q | Driving in → Fig. |
| 3 - | Ball stud |
| q | Removing and installing → Item |
| 4 - | Oil seal for right flange shaft |
| q | Renewing with gearbox installed → Chapter |
| 5 - | Sleeve |
| q | For oil seal. |
| q | Pulling out → Fig. |
| q | Pulling in → Fig. |
| 6 - | Oil filler plug, torque setting → Fig. |
| 7 - | O-ring |
| q | Always renew |
| q | as of 11.02 discontinued in conjunction with ABS |
| 8 - | Speedometer sender -G22- |
| q | From 11.02 in conjunction with ABS replaced by a plug |
| 9 - | Bolt, 5 Nm + turn 90° further |
| q | Always renew |
| 10 - | Shim S2 |
| q | For differential |
| q | Determining thickness → Chapter |
| 11 - | Tapered roller bearing outer race |
| q | For differential |
| q | Pulling out and pressing in → Chapter |
| q | If renewed, adjust differential → Chapter |
| 12 - | Bolt, 5 Nm + turn 90° further |
| q | Always renew |
| 13 - | Tapered roller bearing outer race |
| q | For differential |
| q | Pulling out and pressing in → Chapter |
| q | If renewed, adjust differential → Chapter |
| 14 - | Shim S1 |
| q | For differential |
| q | Always 1 mm thick |
| q | For aluminium gearbox housings only: shim S1 discontinued from gearbox date 04 12 6 → Fig. |
| q | Bearing seat for tapered roller bearing outer race adapted in gearbox housing |
| 15 - | Dowel sleeve |
| q | Qty. 2 |
| 16 - | Gearbox housing |
| q | Made of either aluminium or magnesium. |
| q | For aluminium gearbox housings only: shim S1 discontinued from gearbox date 04 12 6 → Fig. |
| q | Bearing seat for tapered roller bearing outer race adapted in gearbox housing |
| q | If renewed, adjust differential → Chapter |
| q | Allocation → Electronic parts catalogue (ETKA) |
| 17 - | Oil drain plug, torque setting → Fig. |
| 18 - | Oil seal for left flange shaft |
| q | Renewing with gearbox installed → Chapter |
| 19 - | Sleeve |
| q | For selector shaft |
| q | Driving out → Fig. |
| q | Driving in → Fig. |
| 20 - | Magnet |
| q | Held in place by housing joint surface |
| 21 - | Cover plate |
| q | Apply sealant -AMV 188 200 03- before bolting on. |
| 22 - | Retaining ring |
| q | Insert in groove of cylindrical roller bearing → Item. |
| 23 - | Retaining ring |
| q | Insert in groove of cylindrical roller bearing → Item. |
| 24 - | Cylindrical roller bearing |
| q | For input shaft |
| q | Removing and installing → Chapter |
| 25 - | Cylindrical roller bearing |
| q | For output shaft |
| q | Removing and installing → Chapter |
| 26 - | Plug |
| q | Insert into hole in clutch housing. |
| q | Not fitted in all gearboxes |
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