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Repairing the clutch > < Repair information for the manual gearbox 01W/012

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Repairing the clutch control
Repairing the clutch control
Special tools and workshop equipment required
t  Ejection lever -MP3-418 (VW 681)-
t  Drive bushing -T30024 (VW 192)-
t  Copper grease -N 052 159 00-
t  Lithium grease -G 052 150 A2 -
   
1 - Slave cylinder
q   installing → Fig.
q   when installing, press in until the fixing screw Pos. 2 can be installed
q   Tighten the vent valve to 4 Nm.
q   Bleed the clutch system → Chapter
2 - 20 Nm
q   self-locking
q   always replace → Electronic Catalogue of Original Parts
3 - Support
q   fixed to gearbox with slave cylinder
4 - Tappet
q   Lubricate the tappet end with copper grease -N 052 159 00-
5 - Disc spring
q   smaller diameter (curved side) to guide bushing
6 - Gasket ring for drive shaft
q   pull out from the guide bushing with ejection lever -MP3-418-
q   drive up to the stop with drive bushing -T30024-
7 - Screw
q   self-locking
q   always replace → Electronic Catalogue of Original Parts
q   black, only for gearbox made out of aluminium
q   glossy, for gearbox made out of aluminium and magnesium
q   assign → Electronic Catalogue of Original Parts
q   on aluminium gearboxes
t  35 Nm
q   on magnesium gearboxes
t  25 Nm
8 - Clutch release bearing
q   stick on released plastic ring → Fig.
q   Do not wash the bearing, just wipe clean
q   replace noisy bearings → Electronic Catalogue of Original Parts
9 - Clutch release lever
q   before installing, thinly lubricate the contact for the slave cylinder tappet with copper greaset -N 052 159 00-
10 - Retaining spring
q   attach to clutch release lever
11 - Guide bushing
q   before removing/sliding on for protection of the gasket ring Pos. 6, pull the shrink hose over the serration of the drive shaft
q   Fitting position: Oil drain hole points downwards
q   Guide bushings made out of various materials for gearbox made out of aluminium and magnesium
q   assign → Electronic Catalogue of Original Parts
12 - O-ring
q   always replace → Electronic Catalogue of Original Parts
13 - Intermediate piece
14 - Ball pin
q   grease with copper grease -N 052 159 00-
q   Ball pin made out of various materials for gearbox made out of aluminium and magnesium
q   assign → Electronic Catalogue of Original Parts
q   on aluminium gearboxes
t  25 Nm
q   on magnesium gearboxes
t  20 Nm
15 - Gearbox

   
Install clutch slave cylinder
–  Thinly lubricate the tappet contact surface on the clutch release lever with copper grease -N 052 159 00-.
–  Before fitting the slave cylinder in the gearbox housing, the area -a- of the collar must be lubricated with Lithium grease -G 052 150 A2-.
–  Insert the slave cylinder into the hole provided in the gearbox housing, with no more lateral deviation from the direction of action of the tappet, and screw in.
  A30-0037
Repairing clutch release bearing with plastic ring
On clutch release bearing with plastic ring, it is possible that the plastic ring can be released from the clutch release bearing when removing the gearbox or the clutch release bearing, which does not justify replacing the clutch release bearing.
If the plastic ring on the contact surface is deeper than 0.5 mm, the clutch release bearing must be replaced.
–  Before installing the gearbox, re-secure loose plastic ring with adhesive -AMV 195 KD1 01- to the bearing ring.
The three rectangular pegs -arrows- of the plastic ring are inserted into the recesses in the bearing ring.
  N30-0285

Repairing the clutch > < Repair information for the manual gearbox 01W/012