Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U)

Service
Workshop Manual
Polo 2010 ➤
6-speed manual gearbox 02U
Edition 06.2017
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
30 - Clutch
34 - Controls, housing
35 - Gears, shafts
39 - Final drive - differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Polo 2010 ➤
6-speed manual gearbox 02U - Edition 06.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions for vehicles with a start-stop system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Identification of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Identification code, assembly allocation, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Calculating overall gear ratio “i” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.4 Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.6 Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.7 Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.8 Synchro-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.9 Gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.10 Synchromeshed gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.11 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Overview - clutch actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing, installing and adjusting clutch pedal switch F36 . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Removing and installing mounting bracket with master cylinder . . . . . . . . . . . . . . . . . . . . 16
1.5 Removing and installing clutch pedal with over-centre spring, LHD . . . . . . . . . . . . . . . . . . 19
1.6 Removing and installing clutch pedal with extension spring, LHD . . . . . . . . . . . . . . . . . . . . 22
1.7 Removing and installing clutch pedal, RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.8 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.9 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.10 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.11 Removing and installing slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.12 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.4 Removing and installing gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.5 Repairing gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.6 Assembly overview - removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.8 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Contents i
Polo 2010 ➤
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.3 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.3 Assembly overview - removing and installing cover for gearbox housing and 5th and 6th
gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.4 Assembly overview - removing and installing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . 80
4.5 Assembly overview - removing and installing input shaft, output shaft, differential, selector
mechanism and selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.6 Assembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5 Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ii Contents
Polo 2010 ➤
00 – Technical data
1 Safety precautions for vehicles with a
start-stop system
(VRL010533; Edition 06.2017)
WARNING
Injury hazard as a result of automatic engine start in vehicles

with start/stop system.
♦ In vehicles with the start/stop system activated (identifia‐
ble by an indication in the dash panel insert), the engine
can start automatically if the required conditions are met.
♦ When working on the vehicle, therefore, ensure that the
start/stop system is deactivated (switch ignition off, then
switch ignition back on when required).
1. Safety precautions for vehicles with a start-stop system 1

Polo 2010 ➤
2 Identification of gearbox
The 6-speed manual gearbox 02U is installed in the Polo 2010 ►
in conjunction with the 4-cylinder engine.
Allocation ⇒ page 2 .
2.1 Location on gearbox

Code letters and production date -arrow 1- manual gearbox
02U-arrow 2-
Manual gearbox 02U -arrow 2-.
Codes and production date of gearbox

Example: MFV 25 11 9
I I I I
I I I I
Codes Day Month Year (2009)
of manufacture
Additional data provide information about the production facility.
Note
The gearbox code is also included on the vehicle data stickers.
2.2 Identification code, assembly allocation, capacities

Manual gearbox 6-speed 02U
Codes MFV MTH NBU
Manufactured from 11.09 11.09 11.09
to 11.09 08.10 10.12
Allocation Engine 1.2 l - 77 kW 1.2 l - 77 kW 1.2 l - 77 kW
Ratio Final drive 59 : 15 = 3.933 59 : 15 = 3.933 59 : 15 = 3.933
Z2 : Z1
Capacity 2.1 l 2.1 l 2.1 l
Drive shaft flange diameter 100 mm 100 mm 100 mm
2 Rep. gr.00 - Technical data Volkswagen Technical Site: https://vwts.ru

Polo 2010 ➤
The following data can be found in the ⇒ Electronic parts cata‐

logue (ETKA) .⇒
♦ Individual gear ratios
♦ Gear oil
♦ Clutch plate allocation
Manual gearbox 6-speed 02U
Codes NTD PRP PRN
Manufactured from 05.12 10:12 10:12
to 10.12
Allocation Engine 1.2 l - 77 kW 1.2 l - 77 kW 1.2 l - 77 kW
Ratio Final drive 59 : 15 = 3.933 59 : 15 = 3.933 59 : 15 = 3.933
Z2 : Z1
Capacity 2.1 l 2.1 l 2.1 l
Drive shaft flange diameter 100 mm 100 mm 100 mm
The following data can be found in the ⇒ Electronic parts cata‐

logue (ETKA) .⇒
♦ Individual gear ratios
♦ Gear oil
♦ Clutch plate allocation
Volkswagen Technical Site: https://vwts.ru
2. Identification of gearbox 3
Polo 2010 ➤
3 Overview - power transmission

Designation:
-Arrows- indicate direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential
Ratio
-Arrows- indicate direction of travel.
4 Rep. gr.00 - Technical data

Polo 2010 ➤
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
T - Speedometer drive
Replaced by a plug
3. Overview - power transmission 5

Polo 2010 ➤
4 Calculating overall gear ratio “i”

Example:
6th gear Final drive
Drive gear ZG1 = 46 ZA1 = 24
Driven gear ZG2 = 33 ZA2 = 70
i = ZG2 : ZG1 1)
iG = gear ratio = ZG2 : ZG1 = 33 : 46 = 0.717
iA = final drive ratio = ZA2 : ZA1 = 70 : 24 = 2.917
itotal = overall ratio = iG x iA = 0.717 x 2.917 = 2.091
1) Z1 = No. of teeth on driving gear, Z2 = No. of teeth on driven gear

Polo 2010 ➤
5 General repair instructions

Edition 10.2010, version 3.0
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
5.1 Gearbox
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
♦ Following installation, check gear oil level ⇒ page 74 .
♦ Capacity 2.0 l.
5.2 Gaskets and seals

♦ Renew gaskets and seals.
♦ After removing gaskets and seals, always inspect contact sur‐
faces of housing and shaft for burrs resulting from removal or
for other signs of damage.
♦ Before installing radial oil seal, half-fill space between sealing
lips with grease - G 052 128 A1- -arrow-.
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Following installation, check gear oil level ⇒ page 74 .
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
5.3 Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ing paste.
♦ Evenly apply a thin coat of sealing paste - AMV 188 200 03- .
♦ Breather holes must remain free of sealing paste.
5. General repair instructions 7

Polo 2010 ➤
5.4 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins -A-. Installation position: slot longitudinal to
line of force.
5.5 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Always renew self-locking bolts and nuts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Residual locking agent must be removed from all threaded
holes into which self-locking bolts are screwed; this is done
with a screw tap. Otherwise there is a danger of bolts shearing
when subsequently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
5.6 Mountings
♦ Install new tapered roller bearings as supplied and do not lu‐
bricate additionally.
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat bearing inner races to max. 100° C with the inductive
heater - VAS 6414- before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
5.7 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.

Polo 2010 ➤
♦ Install only flawless shims.
5.8 Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always
fit to the same synchromeshed gear.
♦ Check for wear and renew if necessary.
♦ Check grooves -arrow 1- of synchro-ring -A- and inner ring for
flat spots (worn grooves).
♦ If synchro-rings are coated, coating must not be damaged.
♦ If an intermediate ring -B- is installed, check the outer friction
surface -arrow 2- and inner friction surface -arrow 3- of this
intermediate ring for »scoring«, »signs of abnormal wear« and
»blue discolouration (due to overheating)«.
♦ Check cone of synchromeshed gear for »scoring« and »signs
of abnormal wear«.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
5.9 Gear wheels

♦ Before installing, clean and heat with the inductive heater -
VAS 6414- to maximum 100° C.
5.10 Synchromeshed gears

♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
5.11 Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ If the clutch has burnt out, thoroughly clean the clutch housing
as well as the friction surface of flywheel with a cloth to reduce
the smell of burnt linings.
5. General repair instructions 9

Polo 2010 ➤
6 Electrical components
⇒ “6.1 Overview of fitting locations - electrical components”, page
10
6.1 Overview of fitting locations - electrical

components
⇒ “6.1.1 Overview of fitting locations – electrical components,
manual gearbox”, page 10
⇒ “6.1.2 Overview of fitting locations – electrical components,
clutch mechanism”, page 10
6.1.1 Overview of fitting locations – electrical components, manual gearbox
1 - Reversing light switch - F4-

❑ Installation location: be‐
low starter
❑ Removing and installing
⇒ Item 15 (page 81)
2 - Gearbox neutral position
sender - G701-
❑ Fitting location: in area
of selector unit beneath
angled rod for securing
selector shaft
6.1.2 Overview of fitting locations – electrical

components, clutch mechanism
Clutch position sender - G476- (-arrow A- and -arrow B-)
Fitting location:
In engine compartment beneath supply hose -1- on clutch cylinder
-2- above line -3-.
Removing clutch position sender - G476- ⇒ page 18 , installing
⇒ page 19 .

Polo 2010 ➤
Clutch pedal switch - F36-

Location: In passenger compartment, installed from plenum
chamber bulkhead on mounting bracket for clutch pedal
(-arrows-).
Removing and installing clutch pedal switch - F36- ⇒ page 15
6. Electrical components 11
Polo 2010 ➤
30 – Clutch
1 Repairing clutch mechanism
1.1 Overview - clutch actuation
Note
♦ If the vehicle has a radio with anti-theft coding, obtain code before disconnecting battery.
♦ Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnecting battery .
♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery .
♦ Grease all bearing points and contact surfaces.
♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
I - Assembly overview - pedal

cluster ⇒ page 13
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 28
III - Assembly overview - hy‐
draulics (RHD) ⇒ page 30
12 Rep. gr.30 - Clutch

Polo 2010 ➤
1.2 Assembly overview - pedal cluster
1 - Bulkhead
❑ With support for mount‐
ing bracket and master
cylinder
2 - Bush
❑ For upper mounting
hole in mounting brack‐
et
❑ Bushes for lower mount‐
ing hole in mounting
bracket are located in
master cylinder
3 - Mounting bracket
with master cylinder
⇒ page 16
4 - Self-locking hexagon nut,
25 Nm
❑ Qty. 3
❑ Always renew
5 - Clutch pedal switch - F36-
❑ Distinguishing
⇒ page 15
⇒ page 15
6 - Crash bar
❑ Attached to steering col‐
umn
❑ Discontinued in right-
hand drive vehicles from
2009
❑ Allocate components
using ⇒ Electronic parts
catalogue (ETKA)
7 - Bolt
❑ 20 Nm
❑ Discontinued in right-hand drive vehicles from 2009
❑ Allocate components using ⇒ Electronic parts catalogue (ETKA)
8 - Stop
❑ For clutch pedal
9 - Pivot pin
❑ Always renew
10 - Over-centre spring
❑ An extension spring or over-centre spring is installed, depending on equipment variant
❑ Removing and installing, left-hand drive vehicles ⇒ page 19
❑ Removing and installing, RHD ⇒ Removing and installing clutch pedal, ⇒ page 25
11 - Clutch pedal
❑ Removing and installing with over-centre spring, LHD ⇒ page 19
❑ Removing and installing with extension spring, LHD ⇒ page 22
1. Repairing clutch mechanism 13

Polo 2010 ➤
❑ Removing and installing, RHD ⇒ page 25
12 - Bearing bush
13 - Extension spring with vibration damper
❑ An extension spring or over-centre spring is installed, depending on equipment variant
❑ Hooked into mounting bracket ⇒ Item 3 (page 13) and into clutch pedal
❑ Removing and installing ⇒ page 14
14 - Cap
15 - Support
❑ Renew only with master cylinder removed
❑ Detaching ⇒ page 30
❑ Pressing on ⇒ page 30
16 - Master cylinder
17 - Clip
❑ Pull out clip to stop to remove and install pipe/hose line
❑ Pulled out to side on some slave cylinders
18 - Seal
❑ Always renew
❑ Stick to master cylinder
19 - Supply hose
❑ Renewing ⇒ Item 2 (page 29)
20 - Clutch position sender - G476-
❑ for vehicles with start/stop system
❑ Removing ⇒ page 18
❑ Installing ⇒ page 19
❑ Can be checked using “guided fault finding” with the vehicle diagnosis, testing and information system -
VAS 5051-
Removing and installing extension spring

– Insert vibration damper with recess -arrows- from 2nd spring
winding onwards -arrows-.

Polo 2010 ➤
1.3 Removing, installing and adjusting

clutch pedal switch - F36-
To ensure sufficiently secure seating in mounting bracket for
clutch pedal, clutch pedal switch - F36- may be installed only
once.
1.3.1 Removing clutch pedal switch

Removing
– Remove driver side footwell cover ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments, covers and trims .
– Remove footwell vent ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating; removing vents .
Clutch pedal switch is installed from plenum chamber bulkhead.
– Pull connector off clutch pedal switch .
– Turn clutch pedal switch on mounting bracket 45° in
-direction of arrow- and pull out of support.
1.3.2 Installing clutch pedal switch

Distinguishing between clutch pedal switches
Distinguishing between clutch pedal switches
-A- = »without light dome« on • Pull plunger out fully prior to
plunger head -arrow- installation.
-B- = »with light dome« on • Plunger is not allowed to be

plunger head -arrow- pulled out.
• Grease plunger head.

• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
• Clutch pedal must always remain in rest position when clutch
pedal switch is being installed. Clutch pedal is only allowed to
be touched with plunger head of clutch pedal switch during
entire installation procedure.
Clutch pedal switch is installed from plenum chamber bulkhead.

– Insert clutch pedal switch into mounting bracket support and
turn 45° in -direction of arrow-.
– Push connector onto clutch pedal switch .
– Install footwell vent ⇒ Heating, air conditioning; Rep. gr. 80 ;
Repairing heating; removing vents .
– Install driver side footwell cover ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Compartments, covers and trims .

Polo 2010 ➤
1.4 Removing and installing mounting bracket with master cylinder
Special tools and workshop

equipment required
♦ Hose clamp - 3094-

♦ Torque wrench - V.A.G 1331-
♦ Not required, spring-type clip pliers - VAS 5024 A-
Sealing tool - T10249-

Polo 2010 ➤
1.4.1 Removing
LHD vehicles
– Then remove complete air filter housing if it is preventing ac‐
cess to master cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 .
– Remove engine control unit from bulkhead if it is preventing
access to master cylinder ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24
RHD vehicles
In some vehicles, master cylinder is located behind a line for air
conditioning system -arrow-.
An insulation mat is installed in conjunction with some engines.

Appearance may be different from that illustrated.
– Remove heat shield mat -arrows-.
Continuation for all
Note
♦ During the following work, ensure that no brake fluid lands on

longitudinal member or gearbox. If this does happen, clean the
affected areas thoroughly.
♦ Place a lint-free cloth under the master cylinder.
– Clamp off supply hose to master cylinder using hose clamp -

3094- .
– Pull supply hose -1- off master cylinder.
– In addition to clamping off, seal with sealing tool - T10249/1-
if necessary (⇒ figure above).
– Release securing clip -2- using screwdriver or a pointed object
and pull pipe/hose assembly -3- off master cylinder.
Note
Securing clip -2- can also be pulled out to side in some master
cylinders.

Polo 2010 ➤
Vehicles with start/stop system:

– Unclip clutch position sender - G476- on master cylinder
-arrow A- and -arrow B-.
– Remove clutch position sender from master cylinder with elec‐
trical connector connected.
Note
When performing work in the footwell, put cloths on the carpet to

protect it from possible brake fluid spills.
– Remove driver side trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Dash panel .
– If fitted, remove crash bar -arrow-.

– Remove clutch pedal switch - F36- ⇒ page 15 .
– Remove securing nuts -1- and -2-.

– Remove mounting bracket -3-.
1.4.2 Installing
Install in the reverse order of removal, observing the following.

Polo 2010 ➤
Note
♦ Glue new foam seal to master cylinder and mounting bracket.

♦ Renew self-locking nut.
– Install clutch pedal switch - F36- ⇒ page 15 .

– If fitted, install crash bar by tightening securing bolts -arrow-
to specified torque ⇒ Item 7 (page 13) .
– Install driver side trim ⇒ General body repairs, interior; Rep.
Vehicles with start/stop system:

– Insert clutch position sender - G476- into master cylinder with
electrical connector connected. Push it in as far as stop.
• Clutch position sender must clip in -arrow A-.
– To check, pull on clutch position sender -arrow B-.
– After removing hose clamp - 3094- , return supply hose -1- to
its original position, if necessary.
– Press pipe/hose line or plastic line -3- in at connection of mas‐
ter cylinder, until securing clip -2- audibly engages.
– Test line by tugging on it.
– Bleed clutch system ⇒ page 33 .
LHD vehicles
– If engine control unit was removed, fit it onto bulkhead ⇒ Rep.
gr. 23 or ⇒ Rep. gr. 24
– Install air filter housing ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24 , if
removed
1.5 Removing and installing clutch pedal

with over-centre spring, LHD
Note
♦ Install clutch pedal with a new bearing shaft.

♦ If you only wish to remove over-centre spring, then clutch ped‐
al does not need to be separated from master cylinder.
Special tools and workshop equipment required

Polo 2010 ➤
♦ Pliers - T10005-
♦ Allen key, 8 mm AF, commercially available
1.5.1 Removing
– Remove crash bar -arrow-.
– Release master cylinder operating rod from clutch pedal as

follows:
– Pull clutch pedal gently into passenger compartment.
– Press sides of retainer inwards -arrows- using pliers -
T10005- .
– Remove bearing shaft for clutch pedal.
Removing bearing shaft for clutch pedal:
– Break off both locking devices -A- using a screwdriver -1-.

Polo 2010 ➤
-1- = 8 mm hexagon bit

It is also possible to use a 8 mm hexagon key instead of the 8 mm
hexagon bit.
• Turn bearing shaft for clutch pedal to left -arrow- as far as stop.
– Move clutch pedal slightly so that the pivot pin can be pulled
out.
– Take out over-centre spring.
– Remove clutch pedal.
1.5.2 Installing
• Install clutch pedal with a new bearing shaft.
– Make sure that support -2- is located on operating rod -1- of
master cylinder.
– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.
– Insert over-centre spring from side and below, adjacent to

plunger of master cylinder and adjacent to clutch pedal, into
support -A- in mounting bracket.
• Receptacle -arrow- for tip of clutch pedal must be vertical.
– Now position over-centre spring on mounting lug of clutch

pedal -arrow-.

Polo 2010 ➤
– Press on clutch pedal slightly and push new bearing shaft

through.
– Place pins -A- horizontally.
– Turn bearing shaft to right -direction of arrow-.
-1- = Allen key, 8 mm AF.
• Locking devices -B- must audibly engage.
Pins -A- are then vertical.
– Install crash bar. Tighten bolt -arrow- to specified torque

⇒ Item 7 (page 13) .
1.6 Removing and installing clutch pedal

with extension spring, LHD
Note

♦ If you only want to remove extension spring, note ⇒ page 14 .

♦ Pliers - T10005-

Polo 2010 ➤
♦ Hook - 3438-
1.6.1 Removing
– Remove crash bar -arrow-.
– Unhook extension spring.
Right-hand part of figure -arrows- only applies to installation.

follows:
– Pull clutch pedal gently into passenger compartment.
– Press sides of retainer inwards -arrows- using pliers -
T10005- .

Polo 2010 ➤

hexagon bit.
out.
– Remove clutch pedal.
1.6.2 Installing
• Install clutch pedal with a new bearing shaft.
Grease extension spring supports.
– Make sure that support -2- is located on operating rod -1- of
master cylinder.


Polo 2010 ➤
– Hook in extension spring.

– Install crash bar. Tighten bolt -arrow- to specified torque

1.7 Removing and installing clutch pedal,

RHD
Note

♦ If you only wish to remove over-centre spring, then clutch ped‐
al does not need to be separated from master cylinder.

♦ Pliers - T10005-

Polo 2010 ➤
♦ In addition for clutch pedal with extension spring: hook - 3438-
1.7.1 Removing
– Remove mounting bracket with master cylinder ⇒ page 16 .
follows:
– Press sides of retainer inwards -arrows- using pliers - T10005-
and pull gently on clutch pedal.
Clutch pedal with extension spring
– Unhook extension spring. (Shown here with mounting bracket
installed.)
Right-hand part of figure -arrows- only applies to installation.

Clutch pedal with over-centre spring
– Press over-centre spring in -direction of arrow- and remove

downwards.

Polo 2010 ➤

hexagon bit.
out.
1.7.2 Installing
• Insert clutch pedal with new bearing shaft.
– Bring clutch pedal to rest position.
Clutch pedal with over-centre spring
– First insert over-centre spring in back of mounting.

– Now press over-centre spring onto mounting lug of clutch ped‐
al -arrow-.
Clutch pedal with extension spring

Polo 2010 ➤
– Hook in extension spring. (Shown here with mounting bracket

installed.)
– Make sure that support -2- is located on operating rod -1-.

to engage.
– Install mounting bracket ⇒ page 16 .
1.8 Assembly overview - hydraulics (LHD)

Polo 2010 ➤
1 - Brake fluid reservoir

2 - Supply hose
3 - Seal
❑ The seals must be loca‐
ted in supply hose
4 - Master cylinder
⇒ page 32
5 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line
6 - Support
❑ Renew only with master
cylinder removed
❑ Pressing on
⇒ page 30
7 - Mounting bracket with
clutch pedal
8 - Hexagon nut
❑ ⇒ Item 4 (page 13)
9 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 30
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
10 - Pipe/hose line
❑ Determine according to ⇒ Electronic parts catalogue (ETKA) .
❑ To remove, remove ABS control unit with hydraulic unit ⇒ Brake system; Rep. gr. 45 ; Hydraulic unit;
Assembly overview - brake servo and master brake cylinder; Removing and installing control unit and
master brake cylinder
11 - Bracket
❑ Secured to body
12 - Hexagon bolt
13 - Clip
14 - Bleeder valve
❑ Bleeding clutch system ⇒ page 33
15 - Dust cap
16 - Slave cylinder

Polo 2010 ➤
Lever off retainer -A- in direction of arrow.
Carefully press master cylinder operating rod in retainer -A-
Seals and O-rings for pipe and hose lines

Item Material of line connection
1 Line connection with circumferential groove
-arrow 1-
2 Line connection with shoulder -arrow 2-
3 Line connection with shoulder -arrow 2- and cir‐
cumferential groove -arrow 3-
• For line connection having circumferential groove -arrow 1-
and -arrow 3-, a seal or O-ring must be set there.
1.9 Assembly overview - hydraulics (RHD)

Polo 2010 ➤
1 - Brake fluid reservoir

2 - Supply hose
3 - Seal
❑ The seals must be loca‐
ted in supply hose
4 - Master cylinder
⇒ page 32
5 - Clip
❑ Pull clip out to stop to re‐
move pipe/hose assem‐
bly
6 - Support
❑ Renew only with master
cylinder removed
7 - Mounting bracket with
clutch pedal
8 - Hexagon nut
9 - Brake lines
❑ Various number
10 - Bracket
❑ Secured to body
11 - Bracket
❑ Secured to body
❑ For brake lines and
pipe/hose assembly
12 - Pipe/hose line
❑ Determine according to ⇒ Electronic parts catalogue (ETKA) .
13 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adapted to material of line connection ⇒ page 30
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
14 - Hexagon bolt
15 - Clip
16 - Bleeder valve
❑ Bleeding clutch system ⇒ page 33
17 - Dust cap
18 - Slave cylinder

Polo 2010 ➤
1.10 Removing and installing master cylinder

Pliers - T10005-
1.10.1 Removing
Remove mounting bracket with master cylinder ⇒ page 16 .
– Release clutch pedal from master cylinder with pliers -
T10005- .
– Remove master cylinder from mounting bracket.
1.10.2 Installing
– Insert master cylinder into mounting bracket.
– Make sure that support -2- is located on operating rod -1-.
to engage.
Install mounting bracket with master cylinder ⇒ page 16 .
1.11 Removing and installing slave cylinder


Polo 2010 ➤
1.11.1 Removing
– If air filter prevents access to slave cylinder, it must be re‐
moved ⇒ Rep. gr. 23 ; Repairing diesel direct injection system
or ⇒ Rep. gr. 24 ; Repairing injection system .
– Place a lint-free cloth under slave cylinder.
– Pull clip -A- for pipe/hose assembly out of slave cylinder to
stop.
– Pull pipe/hose assembly out of support -C-.
– Pull pipe/hose assembly -B- out from slave cylinder and seal
hose.
– Remove bolts for slave cylinder -arrows- and remove slave
cylinder.
Caution
Do not operate clutch pedal any more.
1.11.2 Installing
– Bolt slave cylinder to gearbox -arrows- ⇒ Item 12 (page 29) .
– Insert pipe/hose assembly -B- into slave cylinder to stop.
– Press in clip -A- to stop.
– Press pipe/hose assembly into support -C- on gearbox.
– Bleed clutch system after installing slave cylinder
⇒ page 33 .
– If the air filter was removed, it must now be reinstalled ⇒ Rep.
gr. 23 ; Repairing diesel direct injection system or ⇒ Rep. gr.
24 ; Repairing injection system
1.12 Bleeding clutch system


Polo 2010 ➤
♦ Brake filling and bleeding equipment - VAS 5234- or
♦ Brake filling and bleeding equipment - VAS 5234-
Note
Prefilling system is not necessary!
Specifications for brake fluid ⇒ Brake systems; Rep. gr. 47 ;

Bleeding brake system .
– If air filter prevents access to slave cylinder, it must be re‐
– Connect brake charge and bleed equipment - VAS 5234- or -
V.A.G 1869- .
To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if
necessary.
– To do this, connect the bleeder hose to the collector bottle of
the brake bleeding device.
– Push bleeder hose -arrow- onto bleeder valve.
– Pressurise system to 2 bar.
– Open bleeder valve.
– Bleed off about 100 cm3 brake fluid.
– Close bleeder valve.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open bleeder valve.
– Bleed off an additional 50 cm3 brake fluid.
– Close bleeder valve.
– Depress clutch pedal several times after completion of bleed‐
ing process.

Polo 2010 ➤
2 Repairing clutch release mechanism
1 - Release bearing
❑ Remove and install to‐
gether with clutch re‐
lease lever
and guide sleeve
⇒ page 36 to
⇒ page 36
❑ Do not wash out bear‐
ing; wipe only
❑ Renew noisy bearings
2 - Bolt, 5 Nm + turn 90° further
❑ Always renew
3 - Clutch release lever
gether with release
bearing
⇒ Item 1 (page 35) and
guide sleeve
⇒ page 36 to
⇒ page 36
❑ Remove old grease
4 - Retaining spring
❑ Secure to clutch release
lever
5 - Guide sleeve
gether with release
bearing
⇒ Item 1 (page 35) and
clutch release lever
⇒ page 36 to
⇒ page 36
6 - Input shaft seal
❑ Renewing ⇒ page 41 ⇒ Item 2 (page 101)
7 - Ball-head pin, 20 Nm
❑ Remove old grease from contact surface of clutch release lever
❑ Lubricate with grease -G 000 100-
8 - Gearbox
9 - Hexagon bolt, 20 Nm
10 - Bracket
❑ Not fitted in all vehicles
11 - Slave cylinder
2. Repairing clutch release mechanism 35

Polo 2010 ➤
Removing and installing clutch release lever with release bearing

and guide sleeve
– Unscrew 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 lev‐
er.
– To install, press release bearing -A- into clutch release lever
until locking lugs -arrows- engage.

Polo 2010 ➤
3 Repairing clutch
♦ Counter-hold tool - 3067-
♦ Centring pin - 3190 A- ⇒ page 40
♦ Centring pin - T10086- ⇒ page 39
♦ Grease for splines - G 000 100-
3. Repairing clutch 37
Polo 2010 ➤
1 - Flywheel
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
⇒ Rep. gr. 13
2 - Clutch plate
❑ Allocate according to ⇒
Electronic parts cata‐
logue “ETKA” .
❑ Installation position:
spring cage faces pres‐
sure plate.
❑ Centring (small crank‐
shaft diameter)
⇒ page 39
❑ Centring (large crank‐
shaft diameter)
⇒ page 40
❑ Lightly grease splines
Note
Clean input shaft splines and, on

used clutch plates, hub splines. Re‐
move corrosion and apply only a
very thin coat of grease - G 000 100-
to input shaft splines. Then, move
the clutch plate back and forth on
the drive shaft until the hub moves
easily on the shaft. Remove excess
grease.
3 - Thrust plate
❑ ⇒ Fig. ““Check ends of diaphragm spring”“ , page 40
❑ ⇒ Fig. ““Check spring connection and riveted fastenings.”“ , page 40
Note
Pressure plates are protected

against corrosion and greased.
Clean contact surface only; other‐
wise the service life of the clutch will
be considerably reduced.
4 - M6 bolt 13 Nm, M7 bolt 20 Nm

❑ Allocation ⇒ Electronic parts catalogue “ETKA” .
❑ Loosen or tighten diagonally in small steps

Polo 2010 ➤
Note
♦ Check whether dowel sleeves for aligning engine and gearbox

are fitted in cylinder block and install if necessary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch
problems and possible noises from the gearbox (rattling of
gears which are not engaged) could occur.
♦ Renew clutch plates and pressure plates with damaged or
loose rivets.
♦ Allocation ⇒ Electronic parts catalogue “ETKA”
♦ Different crankshaft diameters -arrow-!
♦ For engines having a crankshaft with a small diameter, use
centring drift - T10086- ⇒ page 39
♦ For engines having a crankshaft with a large diameter, use
centring mandrel - 3190 A- ⇒ page 40
♦ Installation position of the clutch plate: the protruding spring
cage or the lettering “Getriebeseite” (gearbox end), if present,
must face towards the pressure plate.
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert se‐
curing bolts.
Centring the clutch plate (small crankshaft diameter) and remov‐

ing and installing pressure plate
3. Repairing clutch 39
Polo 2010 ➤
Centring the clutch plate (large crankshaft diameter) and remov‐

ing and installing pressure plate
– Loosen or tighten bolts diagonally in stages.
– Reverse position of counterhold - 3067- when removing.
Check ends of diaphragm spring

• Wear up to half the thickness of the diaphragm spring is per‐
mitted.
Check spring connection and riveted fastenings.

– Check spring connection between pressure plate and cover
for cracks as well as rivet connections for secure seating.
– If pressure plate has damaged springs or loose rivet connec‐
tions -arrows-, it must be renewed.

Polo 2010 ➤
4 Renewing input shaft seal

♦ Removal tool - T20143/1-
♦ Thrust piece - T40008-
♦ Sealing grease - G 052 128 A1-

Procedure
• Gearbox is removed.
– Remove release bearing ⇒ page 82 .
– Lever out oil seal using oil seal extractor lever - T20143/1- .
Note
Do not damage running surface of input shaft for oil seal.
– Clean contact surface and sealing surface.
4. Renewing input shaft seal 41

Polo 2010 ➤
– Fill space between sealing lip and dust lip -arrow- with sealing
grease - G 052 128 A1- .
– Drive in new oil seal to stop, being careful not to cant oil seal.
– Install release bearing ⇒ page 82 .

Polo 2010 ➤
34 – Controls, housing
1 Repairing selector mechanism
1.1 Installation position of selector mechanism

Arrow -A- Gear selection movement
Arrow -B- Gate selection movement
A - Gear selector cable

B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Gearbox selector lever
2 - Deflector lever
1. Repairing selector mechanism 43

Polo 2010 ➤
1.2 Overview of selector mechanism
Note
♦ Note radio code for vehicles with coded radio.

♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Disconnecting and connecting battery .
♦ When reconnecting battery, perform work required after connecting battery ⇒ Electrical system; Rep. gr.
27 ; Disconnecting and connecting battery .
♦ For work on selector mechanism in engine compartment, remove complete air filter housing if it is located
over selector mechanism ⇒ Rep. gr. 23 or ⇒ Rep. gr. 24
♦ Remove selector mechanism to renew selector cables ⇒ page 53 .
♦ Do not kink selector cables.
I - Assembly overview - gear

knob and cover ⇒ page 45
II - Repairing gear lever and
selector housing ⇒ page 47 .
III - Assembly overview - re‐
moving and installing selector
cables ⇒ page 49 .
Removing and installing selector mechanism ⇒ page 53 .

Adjust selector mechanism ⇒ page 56 .
44 Rep. gr.34 - Controls, housing

Polo 2010 ➤
1.3 Assembly overview - gear knob and cover
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
⇒ page 45
3 - Clamp
❑ For securing gear knob
to gear lever
❑ Always renew
❑ Secure to gear knob us‐
ing hose clip pliers -
V.A.G 1275-
4 - Centre console cover
❑ Combined with upper
part of centre console in
one part
❑ Individual in some
equipment versions
5 - Noise insulation
❑ Not fitted in all vehicles
❑ Arrow on noise insula‐
tion points in direction of
travel
❑ Locking lugs are ar‐
ranged at varying inter‐
vals
❑ Therefore it can be installed in only one position
1.4 Removing and installing gear knob and

cover
♦ Removal wedge - 3409-

Polo 2010 ➤
♦ Hose clip pliers - V.A.G 1275-
Removing
– Lever off gaiter using removal wedge - 3409- on alternate
sides -arrows- and pull off upwards.
– Fold boot up over gearstick.
– Open clamp -arrow- and pull off gear knob together with gaiter.
Installing
– Turn gaiter inside out.
The gear knob must be pressed to stop.
– Install gear knob and gaiter and squeeze new clamp -arrow-
together.

Polo 2010 ➤
1.5 Repairing gear lever and selector hous‐

ing

♦ Release tool - T10236-
♦ Press tool - VW 412-
♦ Assembly tool - T10178-
♦ Adapter - 10 - 222 A /25-
♦ - 2- = counter support e.g. from -Kukko- , type 16
♦ Wedge - T10357-
Note
♦ Lubricate bearing positions and sliding surfaces.


Polo 2010 ➤
1 - Securing clip
❑ To remove and install,
press spring down
2 - Compression spring
3 - Seal
❑ Always renew
❑ Between selector hous‐
ing and underbody
❑ Self-adhesive
❑ Bond to selector lever
housing
4 - Gear lever
5 - Dampers
⇒ page 49
6 - Selector housing
❑
7 - Damping washer
❑ Must be located in
groove -arrows- in gear
lever
8 - Seal
❑ Always renew
9 - Floor panel
❑ Bend open tabs to re‐
move
❑ Always renew
❑ Fitting ⇒ page 49
10 - Bush
11 - Gate change cable
❑ Pry off using release tool - T10236-
❑ Press onto gate selector lever inside selector mechanism
❑ Fitting position ⇒ page 43
12 - Gear change cable
❑ Pry off using release tool - T10236-
❑ Press onto gear lever guide inside selector mechanism
13 - Hexagon nut, 25 Nm
❑ Qty. 4

Polo 2010 ➤
Removing and installing damping -arrow-

– Press extension -A- of spring to the left until it is next to damp‐
ing -arrow-.
– Move gear lever to left and pull off damping.
• After installation, damping must contact extensions -A- and
-B-.
Installing base plate to selector housing

– Fit new seal to base plate.
Caution
Risk of damage to selector housing and floor plate.

Only lightly tighten selector housing.
– Secure base plate by bending down tabs -arrows- around cir‐

cumference of base plate (here only tabs on left side of base
plate are marked).
– Tabs can be bent down using wedge - T10357- .
- A- = counter support e.g. from -Kukko- , type 16
1.6 Assembly overview - removing and installing selector cables
Note
♦ Lubricate bearing positions and sliding surfaces.


Polo 2010 ➤
1 - Gear change cable

❑ Connect to cable end-
piece
⇒ Item 12 (page 50) .
❑ Fitting position
⇒ page 43
2 - Gate change cable
❑ Connect to cable end-
piece
⇒ Item 10 (page 50) .
⇒ page 43
3 - Bush
4 - Securing clip
❑ Always renew
❑ Do not damage cables
when removing
5 - Selector housing
6 - Cable support bracket
❑ After installing, adjust
selector mechanism
⇒ page 56
7 - Grommet
❑ Cable support bracket
mounting on gearbox
8 - Spacer
9 - Hexagon bolt, 25 Nm
❑ Qty. 3
❑ For cable support brack‐
et
10 - Cable end-piece
❑ After installing, adjust selector mechanism ⇒ page 56
❑ For gate selector cable to relay lever
❑ Remove from relay lever ⇒ page 53
❑ Press onto relay lever ⇒ page 53
❑ Allocation ⇒ page 51 .
11 - Securing clip
❑ Always renew
12 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
❑ Allocation ⇒ page 51 .
13 - Self-locking hexagon nut, 25 Nm
❑ Always renew
❑ Can be renewed with the selector mechanism installed

Polo 2010 ➤
15 - Slide block
16 - Deflector lever
❑ Remove and install together with cable end-piece ⇒ page 52
17 - Clip
❑ For relay lever
Allocation of cable end-pieces

The holes in the cable end-pieces have different diameters.
Cable end-piece for Dimension “a”
1 - Gear selector cable to 8.5 mm
gearbox selector lever
2. - Gate selector cable to 10 mm
relay lever
Install gearbox selector lever

– When fitting the gearbox selector lever, ensure that the gap
-arrow A- is aligned with the master spline -arrow B-.

Polo 2010 ➤
Installation position of gearbox selector lever/relay lever

1- Gearbox selector lever
2- Relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.
Removing and installing relay lever with cable end-piece

• To remove relay lever, first separate cable end-piece from
gate selector cable.
This will avoid damage to the gate selector cable.
• The cable end-piece can be removed only with the relay lever
removed ⇒ page 53 .
– Pull locking mechanism forward to stop in
-direction of arrow 1-, and then lock it by turning to left in
-direction of arrow 2-.
– Then push relay lever forwards (-in direction of arrow 3-).
– Pull off clip -arrow 1- and remove relay lever together with ca‐
ble end-piece.
Cable end-piece must be located behind catch -arrow 2-.
Note
♦ When installing, lubricate bearing positions and sliding surfa‐

ces.
– Press cable end-piece onto relay lever ⇒ page 53 .

– Install relay lever together with cable end-piece to stop.
• Clip -arrow 1- secures relay lever.
• Ensure proper engagement of clip.
• Cable end-piece must be located behind catch -arrow 2-.

Polo 2010 ➤
Levering cable end-piece for gate selector cable off relay lever
• Relay lever has been removed
– Insert a flat-blade screwdriver -A- between bush -B- and relay
lever.
Press cable end-pieces onto relay lever

• Relay lever has been removed
• Cable end-piece may be pressed only onto bush -arrow-.
• Cable end-piece must move freely on relay lever.
• It must be located behind catch -arrow 2- ⇒ page 52 .
1.7 Removing and installing selector mech‐

anism
1.7.1 Removing

Polo 2010 ➤
♦ Hose clip pliers - V.A.G 1275-
– First check whether a coded radio is fitted. If so, obtain anti-

theft code.
– Disconnect battery earth strap and remove battery with battery
tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
installing battery .
– If the air cleaner is located behind the battery, it must be re‐
– Remove circlip -1-.
– Take gear selector cable -2- off pin.

Polo 2010 ➤
– Separate cable locking mechanism on relay lever -3- from gate

selector cable.
– Pull locking mechanism forward to stop in
-direction of arrow 1-, and then lock it by turning to left in
– Then push relay lever forwards (-in direction of arrow 3-).
– Remove cable support bracket from gearbox -arrows-.

Gearbox selector lever and relay lever with cable end-pieces are
shown removed for clarity of illustration.
– Pry gaiter upwards out of centre console frame using removal
lever - 3409- ⇒ page 45 .
– Then destroy clamp -arrow- and pull off gear knob with gaiter.
– If noise insulation is present, remove it.
– Remove centre console together with securing bracket ⇒
General body repairs, interior; Rep. gr. 68 ; Compartments,
covers and trims; Removing and installing centre console .
– Remove nuts for selector housing from body -arrows-.

– If insulation tray is installed below engine and gearbox, re‐
move it.
– Remove tunnel cross-piece and separate exhaust system ⇒
Rep. gr. 26 ; Exhaust system .
– Remove underbody panels ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Swing selector lever housing down and remove with selector
cables.
1.7.2 Installing

Polo 2010 ➤
– Spread a small amount of grease on pin of gearbox selector

lever.
• Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Renew securing clip -1- each time it is removed.
– Secure gear selector cable -2- with circlip -1-.
– Install relay lever -3- and cable end-piece together
⇒ page 52 .
– Insert gate selector cable in cable end-piece.
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling centre console .
– Renew clamp -arrow-.

– Install underbody panels ⇒ General body repairs, exterior;
Rep. gr. 50 .
– Mount tunnel cross-pieces and front exhaust pipe ⇒ Rep. gr.
26 ; Exhaust system .
Adjust selector mechanism ⇒ page 56 .
– Install complete air filter housing ⇒ Rep. gr. 23 ; Repairing
diesel direct injection system or ⇒ Rep. gr. 24 ; Repairing
injection system .
– Follow procedure after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
1.7.3 Specified torques

Selector housing to body ⇒ Item 13 (page 48)
Selector cable support bracket to gearbox ⇒ Item 9 (page 50)
1.8 Adjusting selector mechanism


Polo 2010 ➤
♦ Pin - T10027 A-
Note
♦ The following points are essential to ensure correct adjust‐

ment of selector mechanism:
♦ Moving parts of operating elements and elements transferring
force must be in proper condition.
♦ Selector mechanism must move freely.
♦ Gearbox, clutch and clutch mechanism must also be in proper
condition.
• Gearbox must be in neutral.

• Angled rod for fixing selector shaft and securing mechanism
for gear selector cable and gate selector cable must be ac‐
cessible.
– Remove air filter housing if it blocks access to angled rod for
fixing selector shaft and to securing mechanism for gear se‐
lector cable and gate selector cable ⇒ Rep. gr. 23 ; Repairing
diesel direct injection system or ⇒ Rep. gr. 24 ; Repairing
injection system .
– Pull locking mechanisms on gate selector cable and gear se‐
lector cable end-pieces forward to stop -direction of arrow 1-
and then turn to left to lock -direction of arrow 2-.
– Check that gate and selector cables are inserted, free of ten‐
sion, into locking devices.

Polo 2010 ➤
Secure selector shaft as follows:

– Press selector shaft down -direction of arrow 1-.
– While pressing selector shaft down, turn angled rod -A- in
-direction of arrow 2-. Press it simultaneously and carefully in‐
wards until it engages in the selector shaft.
– Remove gaiter and any noise insulation from frame for centre
console using removal wedge - 3409- ⇒ page 45 .
– If noise insulation is present, remove it.
Set gear stick as follows:
– Select neutral using gear lever.
– Guide locking pin - T10027 A- through hole -A- into hole -B-.
– Wrap left seat belt -1- around gear lever so that belt holds lev‐
er.
The gear lever is secured by the locking pin - T10027A- (-A-).
In addition, the seat belt presses the gear lever against the stop
for 1st and 2nd gear -direction of arrow-.
This takes all »play out of the selector mechanism«.
– Now turn locking mechanisms on gear selector cable and gate

selector cable end pieces clockwise to stop
The spring presses the locking mechanism into original position

Polo 2010 ➤
– Now turn angled rod -A- back to original position

-direction of arrow-.
Note
The angled rod -A- must be pressed out of selector housing to

stop and point straight up.
– Remove seat belt from selector lever.

– Pull locking pin out of holes -A- and -B-.
– If noise insulation was present, install it.
– Press gaiter into console.
– Check that selector shaft moves freely.
– Check selector mechanism ⇒ page 59 .
– If removed, install complete air filter housing ⇒ Rep. gr. 23 ;
Repairing diesel direct injection system or ⇒ Rep. gr. 24 ;
Repairing injection system .
1.8.1 Function
• With gearbox in neutral, gear lever must rest in gate for 3rd
and 4th gear.
– Operate clutch.
– Select all gears several times. Pay particular attention to op‐
eration of reverse gear lock.
– If it continues to be difficult to engage a gear after repeated
attempts, repeat adjustment procedure of selector mechanism
⇒ page 56 .

Polo 2010 ➤
2 Removing and installing gearbox

equipment required
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /8-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/31-
♦ Support elements for gearbox (determine when setting ad‐
justment plate on gearbox support )
♦ Gearbox lifting tackle - 3336- for transporting gearbox

Polo 2010 ➤
♦ Tensioning strap - T10038-
2. Removing and installing gearbox 61

Polo 2010 ➤

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Grease for splines - G 000 100-
At a later point, support bracket - 10-222 A- will be fitted onto
longitudinal members with adapters - 10 - 222 A /8- .
• To prevent damage to edges of wings, cover lower areas of
both adapters - 10 - 222 A /8- with duct tape -arrow- ⇒ Elec‐
tronic parts catalogue (ETKA, chemical substances) .

Polo 2010 ➤
2.1 Removing gearbox

– Check whether a coded radio is fitted. If so, obtain anti-theft
code.
– Remove complete air filter housing if it is over the gearbox ⇒
Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system
Vehicles with battery in engine compartment
– Remove battery, battery cover and battery tray ⇒ Electrical
system; Rep. gr. 27 ; Removing and installing battery .
Vehicles with battery in luggage compartment .
– Disconnect earth strap ⇒ Electrical system; Rep. gr. 27 ; Re‐
moving and installing battery .
– Remove electrical components above the left assembly
mounting if necessary ⇒ Electrical system; Rep. gr. 27 ; Re‐
– If the lifting eyes of the engine for support bracket - 10 - 222
A- are covered by a component, for example the air filter, it
must be removed now. ⇒ Rep. gr. 23 ; Repairing diesel direct
injection system or ⇒ Rep. gr. 24 ; Repairing injection system .
– Remove securing clip -arrow 1- for gear selector cable from
gearbox selector lever -B-.
– Pull gear selector cable off pin.
– Remove relay lever -A- together with cable end-piece
⇒ page 52 .
– Remove gearbox selector lever -B- by removing nut
-arrow 2-.
– Remove cable support bracket from gearbox -arrows-.

– Then raise and secure gear selector cable and gate selector
cable.

Polo 2010 ➤
– Pull line between master and slave cylinders -A- out of support
-B-, if present, on gearbox.
– Remove slave cylinder -arrows-, lay to side and secure. Do
not disconnect pipes.
Caution
Do not operate clutch pedal any more.
– Gearboxes for vehicles with start-stop system: pull connector

-arrow- off gearbox neutral position sender - G701- .
– Remove cables from starter ⇒ Electrical system; Rep. gr. 27 ;
Starter; Removing and installing starter .
– Then remove upper securing bolt for starter.
– Remove upper engine/gearbox connecting bolts.
– Remove foam pieces or seal from upper edge of left and right
wings ⇒ Body, front; Rep. gr. 50 .
– Set up support bracket - 10-222 A- behind bonnet support.

– Use:
♦ Adapter - 10 - 222 A /8-
♦ Tensioning strap - T10038-
– Position the two adapters - 10 - 222 A /8- :
• Directly in front of plenum chamber cover -arrow-.

Polo 2010 ➤
– Please pay attention to paint on edges -arrows-.

– Secure both adapters - 10 - 222 A /8- with securing straps -
T10038- .
• Tensioning straps must be routed as close as possible to bol‐
ted connection of bonnet hinge to body.
– Take up weight of engine/gearbox assembly on spindles.
– Remove noise insulation tray below engine and gearbox ⇒

General body repairs, exterior; Rep. gr. 50 ; Body - front: As‐
sembly overview - noise insulation .
– Pull connector -1- off reversing light switch - F4- .
– Remove retainer -2- from starter -arrow- and remove wiring
retainer from gearbox, if present.
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Remove cover plate -arrows-.
– Remove pendulum support -arrows A- and -B-.

– Disconnect exhaust system from subframe ⇒ Rep. gr. 26 ;
Exhaust system .
– Disconnect coupling rod -1- from anti-roll bar on both sides ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .

Polo 2010 ➤
– Press anti-roll bar upwards.
– Remove drive shaft heat shield, if present -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts .
– Unbolt drive shafts from gearbox flange shafts and tie up as
high as possible ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .
– Check to see if a cover plate -A- is installed above the right

flange shaft.
– Remove cover plate -arrows-.
– Remove hexagon bolts -arrows- for left assembly mounting

from gearbox mounting.
– Tilt engine and gearbox assembly by lowering spindles of sup‐
port bracket - 10-222 A- .
Note
When lowering engine and gearbox assembly, ensure that gear‐

box does not contact subframe in region of differential.
• Securing bolts -arrows- for gearbox bracket -A- must be ac‐

cessible.

Polo 2010 ➤
– Remove gearbox bracket -A- -arrows-.

– Assemble engine and gearbox support , gearbox support -
3282- , adjustment plate - 3282/31- for “02T” gearbox and
mounting elements as follows:
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
(adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Screw in support elements -A- as illustrated on adjustment

plate.
– Position engine and gearbox jack under vehicle. Arrow -B- on

adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox and lock safety sup‐
port on gearbox.
– Remove engine/gearbox connecting bolt -arrow-.
– Remove engine/gearbox connecting bolt -A- in area of right

flange shaft.
Note
On some engines, the engine/gearbox connecting bolt is below

the right flange shaft.
– Press gearbox off dowel sleeves and carefully swing towards

subframe.
– Have a second mechanic press engine forwards.
– When doing this, observe radiator.
– Turn gearbox downwards in vicinity of differential.

Polo 2010 ➤
– Then carefully lower gearbox. When doing this, guide with

right-hand flange shaft -A- in area of flywheel and intermediate
plate as shown and with left-hand flange shaft -B- in area of
subframe.
– Push left wheel housing liner slightly to left in lower are so that
the gearbox does not contact it.
– When lowering gearbox, change position of gearbox using
spindles of gearbox support - 3282- .
Note
Observe lower connection for coolant hose between radiator and

engine.
2.2 Installing gearbox

– Clean input shaft splines and lightly grease with grease - G000
100- .
The clutch plate must slide easily to and fro on the input shaft.
– Check whether dowel sleeves for aligning engine and gearbox
are fitted in cylinder block and install if necessary.
– Ensure that intermediate plate is correctly seated on engine.
– Assemble engine and gearbox support , gearbox support -
3282- , adjustment plate - 3282/31- for “02T” gearbox and
mounting elements as follows:
– Fit adjustment plate - 3282/31- on gearbox support - 3282-
(adjustment plate fits in only one position).
– Align arms of gearbox support according to holes in adjust‐
ment plate.
– Screw in support elements -A- as illustrated on adjustment
plate.
– Align gearbox parallel to adjustment plate and set on engine
and gearbox jack .
– Lock safety support to gearbox.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
Note
Be careful of all lines when installing gearbox.
– Using spindles of gearbox support - 3282- , tilt gearbox down‐

wards in vicinity of differential.
– Have a second mechanic press engine forwards. When doing
this, observe radiator.

Polo 2010 ➤
– Then carefully raise gearbox. When doing this, guide with

right-hand flange shaft -A- in area of flywheel and intermediate
plate as shown and with left-hand flange shaft -B- in area of
subframe.
– Push left wheel housing liner slightly to left in lower are so that
the gearbox does not contact it.
Note
♦ Observe lower connection for coolant hose between radiator

and engine.
♦ Observe coolant hose between engine and heat exchanger for
heater.
– Insert gearbox.
– Screw in engine/gearbox connecting bolt -A- in area of right

flange shaft.
Note
On some engines, the engine/gearbox connecting bolt is below

the right flange shaft.
– After gearbox has been bolted to engine, remove engine and

gearbox jack from gearbox.
– Install lower engine/gearbox securing bolts.
– Fit gearbox bracket -A- with new bolts -arrows-.

– Moisten bonded rubber mounting of left assembly mounting
and upper section of gearbox bracket with assembly lubrica‐
tion oil ⇒ Electronic Parts Catalogue (ETKA) .
– Align engine and gearbox in installation position.
– Install new bolts -arrows- for left assembly mounting in gear‐

box mounting.
WARNING
Do not remove support bracket - 10-222 A- until all bolts se‐

curing the assembly mounting have been tightened to speci‐
fied torque.
– Install upper engine/gearbox securing bolts.

– Use new bolts for securing pendulum support.
– Have a second mechanic press engine forwards.

Polo 2010 ➤
– Install pendulum support -arrows A- and -B- ⇒ Rep. gr. 40 ;

Assembly overview - subframe, anti-roll bar, suspension links .
– Install cover plate -arrows-.

– Then install drive shafts ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Removing and installing drive shafts .
– Install drive shaft heat shield, if present -arrows- ⇒ Running

– On both sides, bolt coupling rod -1- onto anti-roll bar ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 .
– Reassemble exhaust system ⇒ Rep. gr. 26 ; Exhaust system .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– If necessary, install earth strap on engine/gearbox connecting
bolt.

Polo 2010 ➤
– Install bracket -2- on starter -arrow-.

– Push connector -1- onto reversing light switch - F4- .
– Gearboxes for vehicles with start-stop system: join connector

-arrow- to gearbox neutral position sender - G701- .
– Check for correct installation position of vacuum hose for
brake system, install vacuum hose if necessary ⇒ Rep. gr.
47 .
– Install slave cylinder -C-.

– Press pipe/hose assembly -A- into retainer -B- on gearbox if
necessary.
– Install cable support bracket on gearbox -arrows-.

Polo 2010 ➤
– Mount gearbox selector lever -B- and tighten hexagon nut

-arrow 2- to specified torque ⇒ Item 13 (page 50) .
– Install relay lever -A- together with cable end-piece
⇒ page 52 .
– Spread a small amount of grease on pin of gearbox selector
lever -B-.
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
– Connect gear selector cable to gearbox selector lever
-arrow 1-.
– Adjust selector mechanism ⇒ page 56 .
– Check gear oil ⇒ page 74 .
– Install noise insulation tray below engine and gearbox ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly
overview - noise insulation .
– Insert foam pieces or seal for plenum chamber cover into up‐
per edge of left and right wings ⇒ Body, front; Rep. gr. 50 .
– Remove complete air filter housing if it is over the gearbox ⇒
Rep. gr. 23 ; Repairing diesel direct injection system or ⇒
Rep. gr. 24 ; Repairing injection system
Vehicles with battery in engine compartment
– Install battery tray, battery cover and battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing and installing battery .
Vehicles with battery in luggage compartment .
– Install electrical components above the left assembly mount‐
ing if necessary ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
– Installing earth strap ⇒ Electrical system; Rep. gr. 27 ; Re‐
– Follow procedure after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
– Install air filter ⇒ Rep. gr. 24 ; Removing and installing air
filter .
Note
Note radio code for vehicles with coded radio.
2.3 Specified torques

Gearbox to engine
Item Bolt Quantity Nm
1 M12 x 60 3 80
2 M12 x 130 2 80
♦ Additionally, start‐
er to gearbox
3 M12 x 80 1 80
4 M 10 x 25 2 40
Item -A- for dowel sleeves for centring

Polo 2010 ➤
Gearbox bracket -A- to gearbox

– Renew bolts -arrows-.
– Tighten bolts hand-tight.
– Tighten bolts to specified torque.
Bolts -arrows-: 40 Nm + 90 °
Gearbox to body
– Renew bolts.
– Screw in all bolts hand-tight.
– Tighten bolts -arrows- to specified torque.
Bolts -arrows-: 40 Nm + 90 °
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.

10 ; Removing and installing engine .
Slave cylinder to gearbox ⇒ Item 12 (page 29)

Gearbox selector lever to selector shaft ⇒ Item 13 (page 50)
Selector cable support bracket to gearbox ⇒ Item 9 (page 50)
Pendulum support to subframe and gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40
Drive shaft to flange shaft ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Repairing drive shafts; Removing and installing drive
shafts

Polo 2010 ➤
3 Checking gear oil

♦ Socket, 27 mm - 3257-
Gear oil ⇒ Electronic parts catalogue (ETKA)

– To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– Tighten bolt -arrow- to specified torque ⇒ page 75 .
When filling with oil, note the following:
– Remove oil plug -arrow-
– Top-up gearbox oil to lower edge of filler plug drilling.
– Screw in plug -arrow-.
– Start engine, engage gear and allow gearbox to turn for ap‐
prox. 2 minutes.
– Stop engine and remove plug -arrow-.
– Top up with gear oil to lower edge of filler hole.
– Tighten bolt -arrow- to specified torque ⇒ page 75 .

Polo 2010 ➤
Various versions of oil filler and drain plug

I - Oil filler plug/oil drain plug with multi-point socket head, 25 Nm
II - Oil filler plug/oil drain plug with hexagon socket head, 30 Nm
3. Checking gear oil 75

Polo 2010 ➤
4 Dismantling and assembling gearbox
4.1 Overview - gearbox
1 - 1st gear
2 - 2nd gear
3 - 3rd gear
4 - 4th gear
5 - 5th gear
6 - 6th gear
7 - Gearbox housing cover
8 - Gearbox housing
9 - Reverse gear wheel
10 - Selector mechanism
❑ (Selector forks)
11 - Clutch housing
12 - Input shaft
13 - Output shaft
14 - Differential

Polo 2010 ➤
4.2 Assembly overview

Assembly sequence ⇒ page 82
I - Removing and installing

cover for gearbox housing and
5th and 6th gears
⇒ page 78
II - Removing and installing
clutch housing ⇒ page 80
III - Removing and installing in‐
put shaft, output shaft, differ‐
ential, selector mechanism
and selector forks
⇒ page 81
4. Dismantling and assembling gearbox 77

Polo 2010 ➤
4.3 Assembly overview - removing and installing cover for gearbox housing and
5th and 6th gear
1 - Gearbox housing
❑ Repairing ⇒ page 99
2 - Gear wheel for 5th gear
⇒ page 95
❑ Must be pressed off
⇒ page 122 and on
⇒ page 95 on some
gearboxes
3 - Sleeve
⇒ page 97
5 - Cylindrical roller bearing in‐
ner race
❑ For output shaft
❑ Mark before removing
❑ Do not interchange with
inner race for cylindrical
roller bearing of input
shaft
6 - Bolt
❑ M 8: 30 Nm and turn 90°
further
❑ M10: 75 Nm and turn
45° further
❑ Self-locking
❑ Always renew
❑ With cylindrical roller
bearings for input and
output shafts
❑ Always renew
9 - Bolt
❑ M 8: 30 Nm and turn 90° further
❑ M10: 75 Nm then turn 45° further.
❑ For input shaft
❑ Self-locking
❑ Always renew
10 - Inner race for cylindrical roller bearing with thrust washer
❑ For input shaft

Polo 2010 ➤
11 - Synchromeshed gear for 6th gear

12 - Synchro-ring for 6th gear
13 - Two-part needle bearing
❑ For 6th gear
❑ Is a one-part item in some gearboxes
❑ Allocate according to ⇒ Electronic parts catalogue “ETKA”
❑ Replace together with bushing.
14 - Sleeve
❑ For 6th gear needle bearing
❑ Renew together with needle bearing.
15 - Locking collar with synchro-hub for 5th and 6th gear
❑ Dismantling and assembling ⇒ page 115
16 - Selector fork for 5th and 6th gear
17 - Bearing mounting
❑ for 5th gear selector fork.
❑ Will be damaged during removal of input shaft
❑ Always renew
19 - Synchromeshed gear, 5th gear
20 - Needle bearing
❑ For 5th gear

Polo 2010 ➤
4.4 Assembly overview - removing and installing clutch housing
1 - Countersunk bolt
2 - Flange shaft with compres‐
sion spring
⇒ page 82
❑ Assembling
⇒ page 143
❑ Always renew
4 - Clutch housing
5 - Gearbox housing
6 - Clutch release lever
❑ With guide sleeve and
release bearing
⇒ page 82
7 - Bolt

Polo 2010 ➤
4.5 Assembly overview - removing and installing input shaft, output shaft, dif‐
ferential, selector mechanism and selector forks
1 - Differential
❑ Dismantling and assem‐
bling ⇒ page 145
2 - Gearbox housing
3 - Oil drain plug, torque setting
⇒ page 75
4 - Flange shaft with compres‐
sion spring
⇒ page 82
❑ Assembling
⇒ page 143
5 - Countersunk bolt
❑ Self-locking
❑ Always renew
❑ To secure bearing
mounting with deep
groove ball bearing for
input and output shafts
⇒ Item 18 (page 82) .
7 - Hexagon flange nut, 23 Nm
❑ For selector mechanism
⇒ Item 17 (page 82) .
❑ Self-locking
❑ Always renew
8 - O-ring
❑ Always renew
9 - Pivot pin
❑ Always renew
11 - Selector shaft with selector shaft cover
❑ (Selector unit)
❑ Always renew
13 - Bolt, 6 Nm
14 - Gearbox neutral position sender - G701-
❑ for vehicles with start/stop system
15 - Reversing light switch - F4- , 20 Nm
❑ Changed to captive seal shortly after introduction of gearbox.
16 - Seal
❑ Not fitted in all gearboxes

Polo 2010 ➤
17 - Selector mechanism
❑ (Selector forks)
❑ Dismantling and assembling ⇒ page 110
18 - Input shaft and output shaft with bearing mounting and deep groove ball bearing
❑ If bearing support is separated from gearbox housing, the support must always be renewed
❑ Pressing bearing mounting off and on ⇒ Item 13 (page 116) .
❑ Dismantling and assembling input shaft ⇒ page 115
❑ Dismantling and assembling output shaft ⇒ page 127
19 - Reverse gear shaft
20 - Reverse gear wheel
❑ Note installation position ⇒ page 92
21 - Bolt
❑ For reverse gear shaft.
❑ Always renew
4.6 Assembly sequence

Removing and installing gearbox housing cover, clutch housing,
selector shaft with selector mechanism cover, input shaft, output
shaft, differential and selector mechanism.

Polo 2010 ➤

equipment required
♦ Support clamp - VW 313-

♦ Thrust plate - VW 401-
♦ Gearbox support - 3221A-
♦ or gearbox support - 3221- (modifying ⇒ page 86 )
♦ Guide bolt - T10079-

Polo 2010 ➤

♦ Tube - VW 418 A-
♦ Thrust block - T10083-
♦ Washer - T10083/1-
♦ Drip tray - V.A.G 1306-
♦ If gear wheel for 5th gear was pressed off

Polo 2010 ➤
♦ Thrust plate - 3074-

♦ If gear wheel for 5th gear was not pressed off
♦ Thrust plate - T10375-
♦ Puller - T10309A-
♦ Thrust piece/ adapter - T10309/5-

♦ Grip tool - T10309/4A-
Note
Only use the grip tool - T10309/4A- . Other grip tools might break
when pulling off too forcefully.
♦ Three-arm puller - VAS 251 203- or e.g. three-arm puller -

Kukko 30/1-

Polo 2010 ➤
♦ or two-arm puller - VAS 251 007- or e.g. two-arm puller - Kukko

204/2-
♦ Hexagon socket head bolt - M8 x 15-

♦ or drip tray for workshop hoist - VAS 6208-
♦ Sealant
♦ Allocation ⇒ Electronic parts catalogue (ETKA)
4.6.1 Modifying gearbox support - 3221-

If you are using gearbox support - 3221- :
To secure gearbox 02T on gearbox support - 3221- , a new hole
is required.
Dimensions are given in mm.
– Drill an 11.0 mm ∅ hole -arrow- in gearbox support - 3221- .
– Then, mark gearbox support - 3221- with -3221A- .
– Secure gearbox to gearbox support - 3221A- -arrows-.
4.6.2 Dismantling
– Secure on gearbox support - 3221- or on gearbox support -
3221A- -arrows-.
– Place drip tray - V.A.G 1306- underneath.
– Drain gear oil.

Polo 2010 ➤
– Remove clutch release lever -A- together with release bearing

and guide sleeve -arrows-.
– Remove right flange shaft securing bolt -B-. Screw 2 bolts into
flange and counter hold flange shaft using a lever.
– Remove flange shaft along with spring, thrust washer and ta‐
pered ring.
– Unbolt gearbox housing cover -arrow- and carefully pull it off.
– Pull out pivot pin -1- for 5th and 6th gear selector fork -2- and
remove selector fork.
– Remove bolts -A- for inner bearing races on input and output
shafts, engaging 5th gear -arrow 1- and 1st gear -arrows 2-
and -3-.
– Input shaft and output shaft are locked when both gears are
engaged. Both bolts can now be loosened.
Note
♦ If the shafts are to be reused, clean residual locking material

out of threaded holes using a thread chaser.
♦ Pull off gear wheel for 6th gear with three arm puller - Kukko
30/1- .
♦ If necessary, gear wheel for 6th gear can be pulled off to stop
on spindle with two arm puller - Kukko 204/2- . Then pull off
further with three arm puller - Kukko 30/1- .

Polo 2010 ➤
– Pull off gear wheel for 6th gear with inner race of cylindrical
roller bearing for output shaft.
A - Three-arm puller - Kukko 30/1-
B - Hexagon socket-head bolt - M8 x 15-
Adhere to the sequence for pulling off the following components:
• Synchromeshed gear for 6th gear: pull off together with inner
race of cylindrical roller bearing for input shaft.
• Synchro-hub for 5th and 6th gear: pull off together with inner
race for 6th gear needle bearing.
Use puller - T10309A- .
Synchromeshed gear for 6th gear: pull off together with inner race
of cylindrical roller bearing for input shaft.
– First insert sleeve section - T10309/4A- -2-.
• The half-sleeve must be positioned beneath the synchromesh‐
ed gear for 6th gear.
Note
The force necessary for tightening may be very high. Therefore,

use grip - T10309/4A- .
– If necessary, half sleeve must be pressed to end position.

– Then bring adapter - T10309/5- -3- into position.
– Insert thread insert - T10309/3- -1- in sleeve section and ten‐
sion slightly.
– Now install second sleeve section - T10309/4A- and fit tube -

T10309/2- -3- onto assembly.

Polo 2010 ➤
Then pull off synchro-hub for 5th and 6th gear together with inner
race for needle bearing for 6th gear synchromeshed gear.
– First insert sleeve section - T10309/4A- -2-.
• Half sleeve must be positioned beneath synchro-ring.
– If necessary, half sleeve must be pressed to end position.
– Then bring adapter - T10309/5- -3- into position.
– Insert thread insert - T10309/3- -1- in sleeve section and ten‐
sion slightly.
– Now install second sleeve section - T10309/4A- and fit tube -

T10309/2- -3- onto assembly.
Note
The synchro-ring for 5th gear must always be renewed after it is

pulled off.
– Remove synchromeshed gear for 5th gear.

Polo 2010 ➤
– Unscrew flange shaft securing bolt -1- by screwing 2 bolts into

flange and counter-holding flange shaft with a lever.
– Pull out flange shaft -1- with spring.
– Remove sleeve -2- and needle bearing -4-.
– Unscrew hexagon flange nut -5- for securing reverse gear se‐
lector mechanism.
– Remove bearing mounting securing bolts -6- from input and
output shafts.
5th gear wheel can be removed by hand.
– Remove gear wheel for 5th gear -3-.
5th gear wheel cannot be removed by hand.
– The gear wheel for 5th gear -3- will be pressed off later when
the bearing support for the deep groove ball bearing
⇒ page 122 .
– Turn gearbox in support bracket so that clutch housing is up‐
wards.
– Remove securing bolts from clutch housing side for securing
clutch housing to gearbox housing.
– Remove clutch housing, if necessary carefully levering up all
around along protruding housing flange and alternating be‐
tween sides, being careful not to damage sealing surfaces.
– Do not cant the clutch housing. This prevents damage to roller
bearings and their bearing seats on the input and output
shafts.
– Remove differential -A- from gearbox housing.

Polo 2010 ➤
– Gearboxes for vehicles with start-stop system: remove gear‐

box neutral position sender - G701- -arrow-.
– Remove selector shaft with selector cover -A-. Place selector

shaft in neutral. Then remove bolts -arrows- and pull selector
shaft out of gearbox housing.
– Remove pivot pins -B- located on underside of gearbox.
– Screw out reversing light switch - F4- -C-.
– Remove bolt -A- for securing reverse gear wheel shaft.

– Remove pivot pins -B- located on bottom of gearbox.
Note
Do not remove sealing cover -arrow- when dismantling gearbox.
5th gear wheel cannot be removed.
– Press out input shaft, output shaft with gear wheel for 5th gear
-A-, bearing mounting, selector mechanism (selector forks)
and reverse gear together.
Note
♦ Position gearbox housing so that dowel sleeves in the gearbox

will not be damaged.
♦ When pressing out, get help from second mechanic to ensure
components do not fall out.
5th gear wheel can be removed.

Polo 2010 ➤
– Press out input shaft, output shaft with bearing mounting, se‐
lector mechanism (selector forks) and reverse gear together.
Note
♦ Position gearbox housing so that dowel sleeves in the gearbox

will not be damaged.
♦ When pressing out, get help from second mechanic to ensure
components do not fall out.

– Press input and output shafts, together with gear wheel for 5th
gear, off deep groove ball bearing ⇒ page 122 .
– Press input and output shafts, without gear wheel for 5th gear,
off bearing mounting with deep groove ball bearing
⇒ page 122 .
4.6.3 Installing
Note
♦ Press bearing mounting with deep groove ball bearing onto

input shaft and output shaft ⇒ page 126 .
♦ Press needle roller bearing sleeve for synchromeshed gear for
5th gear onto input shaft ⇒ page 126 .
5th gear wheel is located on output shaft.

– Position assembled components, input shaft -2- and output
shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10080- .
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
ing collars.
– Install reverse gear shaft -3- with reverse gear.
Installation position of reverse gear wheel: smooth side faces
downwards, collar and »chamfered teeth« face towards clutch
end.
– Screw guide pin - T10079- onto stud (secures reverse gear)
-arrow-.
5th gear wheel is not located on output shaft.

Polo 2010 ➤
– Position assembled components, input shaft -2- and output

shaft -1- with bearing mounting for deep groove ball bearing,
in thrust piece - T10080- .
– Insert selector mechanism (selector forks) -4- in the shaft lock‐
ing collars.
– Install reverse gear shaft -3- with reverse gear.
Installation position of reverse gear wheel: smooth side faces
downwards, collar and »chamfered teeth« face towards clutch
end.
– Screw guide pin - T10079- onto stud (secures reverse gear)
-arrow-.

– Insert components together in gearbox housing. To do this,
guide guide pin - T10079- through hole for attachment of se‐
lector mechanism in gearbox housing.
– Remove guide pin - T10079- .
Note the following before pressing in:
♦ Selector forks engage correctly in locking collars.

♦ Check dimension -a- for output shaft teeth.
Note
♦ Due to different spline heights, dimension -a-, output shafts of

individual gearboxes have different lengths.
♦ A shim - T10083/1- (3 mm thick) may have to be fitted on the
input shaft to ensure that the input shaft and the output shaft
are always pressed in evenly.
♦ This is the reason why dimension -a- for output shaft teeth
must be measured.
Dimension -a- = 30.6 mm

Placing shim - T10083/1- onto input shaft ⇒ page 94

Polo 2010 ➤
Place shim - T10083/1- onto input shaft and carefully press in

bearing mounting together with input shaft and output shaft to
stop
Carefully press in bearing mounting together with input shaft and

output shaft to stop.
– Install bolt -A- for securing reverse gear wheel shaft.

– Install pivot pin -B- in bottom of gearbox.
– Screw in reversing light switch - F4- -C-.

– Install pivot pin -B- in top of gearbox.
– Place selector plates in neutral.
– Apply sealant - AMV 188 200 03- evenly to sealing surface of
selector mechanism cover.
– Install selector shaft with selector cover -A-. Then tighten bolts
-arrows-.

Polo 2010 ➤
– Gearboxes for vehicles with Start/Stop system: fit gearbox

neutral position sender - G701- -arrow- and tighten securing
bolt to specified torque ⇒ Item 13 (page 81) .
– Using new bolts -A-, tighten bearing mounting for input and
output shafts.
Note
Tighten bolts to specified torque, working from centre outwards

using alternate sequence.
– Tighten hexagon flange nut -B- for securing selector mecha‐

nism (selector forks).
– Insert input and output shafts together with gearbox housing
into thrust block - T10083- .
Installation position, 5th gear wheel

High shoulder -arrow- faces away from gearbox housing.
Install 5th gear wheel -1- and sleeve -2-, when it was removed by
hand.
Press on gear wheel for 5th gear, when it was pressed off.
– Set sleeve on gear wheel for 5th gear ⇒ item -2- on previous
figure.
– Set 5th gear synchromeshed gear with synchro-ring for 5th
gear and needle bearing in place ⇒ page 96 item -1-.

Polo 2010 ➤
Installation position of synchro-hub/locking collar for 5th and 6th

gears
The high shoulder -arrow- faces 5th gear and gearbox housing.
Pressing on locking collar and synchro-hub for 5th and 6th gears:
5th gear synchromeshed gear (item -1-) with synchro-ring for 5th
gear and needle bearing are in place
WARNING
Wear protective gloves.
– Heat inner race for needle bearing for 6th gear to maximum
100° C and press on.
– Install synchro-ring for 6th gear.
– Install synchromeshed gear for 6th gear with needle bearing.
– Heat cylindrical roller bearing inner race -A- to maximum 100 °

C and drive onto input shaft.
WARNING

Polo 2010 ➤
Installation position of 6th gear wheel:

Higher collar faces toward 5th gear wheel.
– Move locking collar -A- for 5th and 6th gear to neutral. This
allows the 6th gear synchromeshed gear to turn when the gear
wheel for 6th gear is pressed on.
WARNING
– Heat gear wheel for 6th gear to maximum 100°C.

– Press on gear wheel for 6th gear, being careful that teeth of
gear wheel -B- for 6th gear and synchronised gear for 6th gear
-C- mesh.
– Heat cylindrical roller bearing inner race -A- to maximum 100°

C and press onto output shaft.
– Insert magnet in gearbox housing ⇒ page 99 .
– Install differential -A-.

– Apply sealant - AMV 188 200 03- evenly to sealing surface.
– Secure clutch housing to gearbox housing.
– Turn gearbox in support bracket so that gearbox housing is
upwards.
– Turn gearbox in support bracket so that gearbox housing is
upwards.

Polo 2010 ➤
– Before tightening securing bolts -A-, engage 2 gears

(-arrows 1- through -3-).
– Insert selector fork for 5th and 6th gears -2- and push pivot pin
-1- in to stop -direction of arrow-.
– Apply sealant - AMV 188 200 03- evenly to sealing surface.
– Tighten gearbox housing cover.
– Install both flange shafts with springs, thrust washers and ta‐
pered rings.
– Install clutch release lever together with release bearing and
guide sleeve ⇒ page 36 .

Polo 2010 ➤
5 Repairing gearbox housing and clutch housing

equipment required
♦ Press tool - VW 408 A-

♦ or drift - 2026-
♦ Spacer sleeve - VW 472/2-
♦ Centring mandrel - 12 - 551-
♦ Thrust piece - 30 - 555-
♦ Spindle from assembly tool - 3066-
♦ Thrust piece - 3124-
5. Repairing gearbox housing and clutch housing 99

Polo 2010 ➤
♦ Gearbox support - 3221- (modifying ⇒ page 86 )

♦ Multi-point bit XZN 12 - 3357-
♦ Puller - Kukko 18/1- -2-
♦ Splitter - Kukko 17/1- -3-
♦ Removal tool - T20143/1-

Polo 2010 ➤
1 - Clutch housing
❑ If renewed, adjust differ‐
ential ⇒ page 151
2 - Input shaft seal
❑ Use oil seal extractor
lever - T20143/1- to lev‐
er out
❑ Driving in ⇒ page 102
3 - Ball-head pin
4 - Oil seal for right flange shaft
❑ Renewing with gearbox
installed ⇒ page 139
5 - Sleeve
❑ For oil seal.
❑ Pulling in ⇒ page 103
6 - Oil filler plug, torque setting
⇒ page 75
7 - O-ring
❑ Always renew, if part of
original equipment
8 - Plug
❑ Always renew
10 - Shim
❑ For differential
❑ Determining thickness
⇒ page 151
11 - Tapered roller bearing outer race
❑ Pulling out and pressing in ⇒ page 143
❑ If renewed, adjust differential ⇒ page 151
❑ Always renew
❑ Pulling out and pressing in ⇒ page 145
14 - Dowel sleeve
❑ Qty. 2
15 - Gearbox housing
16 - Oil drain plug, torque setting ⇒ page 75
17 - Oil seal for left flange shaft
❑ Renewing with gearbox installed ⇒ page 137

Polo 2010 ➤
18 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ Fig. ⇒ page 103
19 - Magnet
❑ Held in place by housing joint surface
20 - Sealing cover
❑ Apply sealant - AMV 188 200 03- before bolting on.
21 - Retaining ring
❑ Insert in groove of cylindrical roller bearing ⇒ Item 24 (page 102) .
22 - Retaining ring
❑ Insert in groove of cylindrical roller bearing ⇒ Item 23 (page 102) .
23 - Cylindrical roller bearing
❑ For input shaft
Driving in input shaft oil seal flush
Pulling out sleeve for seal

– Fit spacer sleeve - VW 472/2- and press tool - 30 - 555- onto
differential.
A - Puller , e.g. -Kukko 18/1-
B - Splitter, 12 … 75 mm , e.g. -Kukko 17/1-

Polo 2010 ➤
Pulling in sleeve for seal

A - Screw spindle from assembly device - 3066- into threaded
piece of differential.
B - M12 nut with washer
– Pull in sleeve to stop using thrust piece - 3124- by turning nut
-B-.
Note
With gearbox dismantled, press sleeve in to stop using thrust

piece - 3124- .
Driving out selector shaft sleeve -A-
Driving in selector shaft sleeve -A-

The sleeve -A- for selector shaft can also be driven in using drift
- 2026- .

Polo 2010 ➤
6 Repairing gearbox housing cover

equipment required

♦ Drift sleeve - 40 - 21-
♦ Support bridge - 2011-
♦ -1- Internal puller - Kukko 21/6-
♦ -4- Counter support - Kukko 22/2-
♦ E.g. hot-air blower - V.A.G 1416-

Polo 2010 ➤
1 - Countersunk head bolt,

2 Nm
❑ Tighten diagonally and
alternately.
2 - Mounting plate
❑ For securing cylindrical
roller bearings
countersinks for coun‐
tersunk head bolts face
gearbox housing
❑ Not used with all gear‐
boxes, in which case se‐
curing with bolts
⇒ page 106
❑ For input shaft
cylindrical roller bearing
for output shaft
❑ Pressing in
⇒ page 106 .
❑ Different locking ele‐
ment ⇒ page 106
cylindrical roller bearing
for input shaft
❑ Pressing in
⇒ page 106 .
❑ Different locking ele‐
ment ⇒ page 106
Pulling cylindrical roller bearing out of gearbox housing cover

A - Internal puller, 37…46 mm , e.g. -Kukko 21/6-
B - Counter support , e.g. -Kukko 22/2-
6. Repairing gearbox housing cover 105

Polo 2010 ➤
Pressing cylindrical roller bearing into gearbox housing cover

– Heat gearbox housing cover with, for example, hot air blower
- V.A.G 1416- to about 100 °C in vicinity of bearing seat.
– Insert cylindrical roller bearing in heated housing and press in
using workshop press until heat exchange has taken place.
Note
Cylindrical roller bearings must be pressed into cover to stop. Do

not use mounting plate to press bearings by tightening bolts.
– Securing cylindrical roller bearings.
Different locking elements for cylindrical roller bearings

The cover was adapted.
Locking element Threaded holes in cover
1. - Securing with mounting plate 6
-A- and countersunk head bolt
M 4 x 14 -arrows-
2. - Securing with countersunk 2
head bolt M 4 x 12 -arrows-

Polo 2010 ➤
7 Repairing selector unit

♦ Tube - T10203-
♦ Tube - VW 423-
7. Repairing selector unit 107

Polo 2010 ➤
1 - Sleeve
❑ For selector shaft
❑ Driving out ⇒ Fig.
⇒ page 103
2 - Selector shaft with selector
shaft cover
❑ Renew together
3 - Angled rod
❑ For adjusting selector
mechanism
4 - Deflector lever
❑ Installing
5 - Clip
6 - Seal
❑ Lever out with a screw‐
driver
7 - Cap
❑ For gearbox breather
❑ Installing
9 - Hexagon nut
❑ ⇒ Item 13 (page 50)
Removing angled rod -A- from selector shaft cover

– Remove outer part of angled rod.
– Then carefully lever out angled rod using a screwdriver.

Polo 2010 ➤
Drive angled rod -A- into selector shaft cover

Installation position:
Marking -1- aligns with marking -2- on selector cover.
Inserting oil seal -A- onto stop
7. Repairing selector unit 109

Polo 2010 ➤
8 Dismantling and assembling selector forks

equipment required

♦ Thrust piece - 3290/1-
♦ Assembly tool - 3301-
♦ Thrust piece - VW 431-
♦ Drift - 10 - 206-

Polo 2010 ➤
♦ Release lever - 80–200-
♦ Assembly mandrel - 10 - 508-
♦ Tensioning device - 2070-
Note
It is not necessary to dismantle the selector fork group ⇒ Item 1 (page 112) in order to dismantle and assemble
selector segments, lock washers and angular contact ball bearings.
8. Dismantling and assembling selector forks 111

Polo 2010 ➤
1 - Selector fork group with se‐

lector plate
2 - Selector segment for 3rd
and 4th gear
❑ After installation, selec‐
tor segment must still ro‐
tate freely
❑ Identification
⇒ page 113
3 - Angular contact ball bearing
❑ Qty. 4
❑ Press inner race into
outer race ⇒ page 114
4 - Clamping washer
❑ Always renew
5 - 1st/2nd gear selector seg‐
ment
❑ Identification
⇒ page 113
❑ After lock washer is in‐
stalled, segment must
still rotate freely
❑ Selector fork with selec‐
tor segment
⇒ page 113
6 - Selector fork for 5th and 6th
gears with selector segments
❑ Selector segment is per‐
manently connected to
selector fork.
❑ Identification ⇒ page 113
7 - Bearing mounting
❑ For selector fork for 5th and 6th gears

Polo 2010 ➤
Identification of selector segments and selector fork 5/6 gear with

selector segments
Dimension -a-
1- Selector segment for 1st and 2nd gears = 10.0 mm
2- Selector segment for 3rd and 4th gears = 78.6 mm
3- Selector fork for 5th and 6th gears with selector segments
= 79.5 mm
Selector fork for 1st and 2nd gears with selector segments
Dimension -a- = 78 mm
Removing lock washer

– Clamp selector fork in vice with protective jaw covers -B-.
– Lever off lock washer -A- in direction of arrow.
Installing lock washer

– Press lock washer into groove of detent segment using socket
and spinner handle.
Note
After lock washer is installed, detent segment must still rotate

freely.
A - Spinner handle with 10 mm socket

B - Protective jaw covers
8. Dismantling and assembling selector forks 113

Polo 2010 ➤
Removing angular contact ball bearing
Note
When removing and installing angular contact ball bearing, do not

bend selector forks.
Pressing inner race -A- of angular contact ball bearing into outer
race
Inner race must engage in outer race.
Pulling angular contact ball bearing into selector fork to stop

Depression in thrust piece - 3290/1- faces ball bearing.

Polo 2010 ➤
35 – Gears, shafts
1 Input shaft
1.1 Assembly overview - input shaft

Dismantling and assembling input shaft ⇒ page 118
Note
♦ When installing new gears or new input shaft, refer to ⇒ Electronic Parts Catalogue “ETKA” and technical
data.
♦ Install all bearings, synchromeshed gears and synchro-rings on input shaft with gear oil.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
1 - Bolt
⇒ page 78
2 - Inner race for cylindrical roll‐
er bearing with thrust washer
⇒ page 82
3 - Synchromeshed gear for
6th gear
❑ Check for wear
⇒ page 123
5 - Needle bearing
❑ For 6th gear
❑ Is a two-part item in
some gearboxes
❑ Renew together with
6 - Sleeve
❑ For 6th gear needle
bearing.
❑ Renew together with
⇒ Item 5 (page 115) .
⇒ page 82
7 - Locking collar with synchro-
hub for 5th and 6th gear
⇒ page 82
❑ Dismantling
⇒ page 126
❑ Assembling locking col‐
lar and synchro-hub for 5th and 6th gear ⇒ page 126 ⇒ page 126 .
1. Input shaft 115

Polo 2010 ➤

❑ Will be damaged during removal of input shaft
❑ Always renew
❑ Check for wear ⇒ page 123
9 - Synchromeshed gear, 5th gear
10 - Needle bearing
❑ For 5th gear
❑ Renew together with ⇒ Item 11 (page 116)
11 - Sleeve
❑ For 5th gear needle bearing
❑ Press off with bearing support and deep groove ball bearing ⇒ page 122
13 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing support
❑ Press off without gear wheel for 5th gear ⇒ page 122
❑ Press off with gear wheel for 5th gear ⇒ page 122 ⇒ page 122
14 - Input shaft
❑ Clean residual locking fluid from threaded hole in input shaft using a thread chaser.
15 - Needle bearing
❑ For 3rd gear
16 - Synchromeshed gear for 3rd gear
17 - Synchro-ring for 3rd gear
18 - Locking collar with synchro-hub for 3rd and 4th gear
❑ Press off with 3rd gear synchromeshed gear ⇒ page 122
❑ Dismantling ⇒ page 123
❑ Installation position, locking collar and synchro-hub ⇒ page 123
❑ Assembling ⇒ page 123 .
19 - Sleeve
❑ for 4th gear needle bearing
❑ Renew together with ⇒ Item 20 (page 116) .
❑ Press off with 3rd gear synchromeshed gear ⇒ page 122
20 - Needle bearing
❑ For 4th gear
116 Rep. gr.35 - Gears, shafts

Polo 2010 ➤
22 - Synchromeshed gear for 4th gear

23 - Thrust washer
24 - Cylindrical roller bearing inner race
❑ Pressing off ⇒ page 122
25 - Retaining ring
❑ Renew
❑ Determining thickness ⇒ page 125
❑ With retaining ring
❑ Pressing in ⇒ page 122 .
❑ Installation position: retaining ring in bearing faces input shaft
27 - Clutch housing
28 - Spring
29 - 3rd and 4th gear locking collar
30 - 3rd and 4th gear synchro-hub
31 - Locking pieces (qty. 3)
32 - Spring
34 - Synchro-hub for 5th and 6th gears
35 - Locking collar for 5th and 6th gears
1. Input shaft 117

Polo 2010 ➤
1.2 Dismantling and assembling input shaft

equipment required

♦ Tube - VW 415 A-
♦ Tube - VW 422-

Polo 2010 ➤

♦ Tube - VW 516-
♦ Extension - 30 - 23-
1. Input shaft 119

Polo 2010 ➤
♦ Washer - T10083/1-

Polo 2010 ➤
♦ Thrust block - T10083-

♦ Thrust plate - T10084 A-
♦ -1- Internal puller - Kukko 21/5-
♦ -4- Counter support - Kukko 22/1-
Dismantling input shaft
Pulling cylindrical roller bearing out of clutch housing
– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
A - Counter support , e.g. -Kukko 22/1-
B - Internal puller, 30…37 mm , e.g. -Kukko 21/5-
1. Input shaft 121

Polo 2010 ➤
Pressing cylindrical roller bearing into clutch housing

– Support gearbox housing with tube - VW 415 A- (not visible
here) directly below bearing support.
– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
When 5th gear wheel -A- cannot be removed by hand.
Pressing off bearing mounting with deep groove ball bearing and
gear wheel for 5th gear -A-
– Slide locking collar for 1st and 2nd gear towards 2nd gear.
– Then slide thrust plate - T10084 A- sideways onto input shaft
to stop.
When 5th gear wheel can be removed by hand.
Pressing off bearing mounting with deep groove ball bearing

to stop.
– Remove retaining ring.
Pressing off cylindrical roller bearing inner race

– Press off cylindrical roller bearing inner race together with
♦ Thrust washer,
♦ 4th gear synchromeshed gear with needle bearing,
♦ Locking collar and synchro-ring for 3rd and 4th gears and
♦ 3rd gear synchromeshed gear.
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub ⇒ page 123 .
Assembling input shaft

Polo 2010 ➤
Dismantling and assembling 3rd and 4th gear locking collar and
synchro-hub
1- Spring
2- Sliding sleeve
3- Synchro-hub
4- Locking piece
– Slide locking collar over synchro-hub.
Deeper notches -arrow A- for locking pieces in synchro-hub and
notches -arrow B- in locking collar must align.
Assembling locking collar and synchro-hub for 3rd and 4th gears
• Locking collar has been pushed over synchro-hub.
– Insert locking pieces in deeper notches -arrows- and install
springs offset 120°. Angled end of spring must locate in hollow
locking piece.
Installation position of locking collar with synchro-hub for 3rd and

4th gear
Groove on top -arrow- faces 4th gear.
Checking synchro-ring for wear

– Press synchro-ring onto cone of synchromeshed gear and
measure gap “a” using feeler gauge.
Gap -a- Installation dimen‐ Wear limit
sion
3rd, 4th, 5th and 1.1 … 1.7 mm 0.5 mm
6th gear
– Install synchromeshed gear for 3rd gear with needle bearing
and synchro-ring.
1. Input shaft 123

Polo 2010 ➤
Pressing on synchro-hub with locking collar for 3rd and 4th gears
Installation position: high inside collar faces 3rd gear synchro‐
meshed gear.
Pressing on sleeve -A- for 4th gear needle bearing

– Fit 4th gear needle bearing, synchromeshed gear for 4th gear
and thrust washer.
Pressing on inner race -A- for cylindrical roller bearing

Polo 2010 ➤
Determining thickness of retaining ring

– Insert a 2.0 mm thick retaining ring -A- in groove of input shaft
and press upwards -arrow-.
– Measure distance between inner race -B- and installed retain‐
ing ring-A- using feeler gauge -C-.
– Remove retaining ring (only used for measuring purposes).
– Determine retaining ring from table.
Note
Allocate retaining rings according to ⇒ Electronic parts catalogue

“ETKA” .
The following securing clips are available:

Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
0.05 to 0.14 2.0 0.05 to 0.15
0.15 to 0.24 2.1 0.05 to 0.15
0.25 to 0.34 2.2 0.05 to 0.15
0.35 to 0.44 2.3 0.05 to 0.15
0.45 to 0.51 2.4 0.05 to 0.10
Press bearing mounting with deep groove ball bearing onto input
shaft and output shaft.
Note
♦ Due to different spline heights, dimension -a-, output shafts of

individual gearboxes have different lengths (shown here with
shafts installed).
♦ To ensure that bearing support is always evenly pressed onto
shafts, it is necessary for shafts always to be inserted evenly
into thrust block - T10083- .
♦ If necessary, insert a shim - T10083/1- (3 mm thick) into
mounting hole for input shaft ⇒ page 125 .
♦ This is the reason why dimension -a- for output shaft teeth
must be measured.
Dimension -a- = 30.6 mm

Insert shim - T10083/1- ⇒ page 125
Fit shim - T10083/1- .
1. Input shaft 125

Polo 2010 ➤
Pressing on bearing support

– Heat inner bearing mounting to approx. 100 °C before press‐
ing on.
WARNING
Pressing on sleeve -A- for 5th gear needle bearing
Dismantling and assembling locking collar and synchro-hub for

5th and 6th gear
1- Spring
2- Locking piece
3- Synchro-hub installation position: groove on face
-arrow A- and wide shoulder -arrow B- must face 5th gear.
4- Sliding sleeve
Deeper notches -arrow C- for locking pieces in synchro-hub and
notches -arrow D- in locking collar must align.
Assembling locking collar and synchro-hub for 5th and 6th gears
– Insert locking pieces in deeper notches -arrows- and install
springs offset 120°.
• Angled end of spring must locate in hollow locking piece.

Polo 2010 ➤
2 Output shaft
2.1 Assembly overview - output shaft

Dismantling and assembling output shaft ⇒ page 130
Note
♦ When installing new gears or new output shaft, refer to ⇒ Electronic Parts Catalogue “ETKA” and technical
data.
♦ Install all bearings, synchromeshed gears and synchro-rings on output shaft with gear oil.
♦ Do not interchange synchro-rings. When reusing always fit to the original gear.
1 - Clutch housing
❑ With retaining ring
❑ Pressing in
⇒ page 131 .
❑ Installation position: re‐
taining ring in bearing
faces output shaft
3 - Output shaft
❑ If an inner race as bear‐
ing seat for cylindrical
roller bearing (item
⇒ Item 2 (page 127) ) is
present, it cannot be re‐
moved from output
shaft.
❑ Check bearing seat or
inner race for cylindrical
roller bearing for scoring
and damage.
❑ If cylindrical roller bear‐
ing inner race or bearing
seat is damaged or
scored, renew output
shaft and cylindrical roll‐
er bearing together.
shoulder faces 3rd gear
⇒ page 133
5 - Retaining ring
6 - Retaining ring
7 - Gear wheel for 3rd gear
❑ Installation position: shoulder faces 4th gear ⇒ page 133
2. Output shaft 127

Polo 2010 ➤
8 - Retaining ring
9 - Synchromeshed gear, 2nd gear
10 - Needle bearing
❑ For 2nd gear
11 - Bearing inner race for 2nd gear
12 - Outer bearing race for 2nd gear
❑ Set on inner ring ⇒ Item 11 (page 128) .
❑ Renew if scored
13 - Synchro-ring for 2nd gear
14 - Locking collar with synchro-hub for 1st and 2nd gear
❑ After removing retaining ring ⇒ Item 15 (page 128) , press off with 2nd gear synchromeshed gear
⇒ page 132
❑ Dismantling ⇒ page 134
❑ Assembling locking collar and synchro-hub ⇒ page 134 and ⇒ page 134
15 - Retaining ring
❑ Renew after removal
❑ Pressing out ⇒ page 132
16 - Synchro-ring for 1st gear
❑ Assemble so that notches engage in locking pieces of locking collar ⇒ Item 14 (page 128) .
17 - Outer ring for 1st gear
❑ Insert in synchro-ring ⇒ Item 16 (page 128) . Installation position ⇒ page 135 .
❑ Renew if scored
18 - Inner ring for 1st gear
❑ Check lugs for scoring
19 - Needle bearing
❑ For 1st gear
20 - Synchromeshed gear, 1st gear
21 - Bearing mounting with deep groove ball bearing
❑ Renew deep groove ball bearing only together with bearing support
❑ Press off without gear wheel for 5th gear ⇒ page 122
❑ Press off with gear wheel for 5th gear ⇒ page 122

Polo 2010 ➤
23 - Bolt
24 - Cylindrical roller bearing inner race
❑ Mark before removing
❑ Do not interchange with inner race for cylindrical roller bearing of input shaft
❑ Installation position: ⇒ page 97 .
26 - Sleeve
❑ Installation position: ⇒ page 95 .
28 - Spring
29 - Sliding sleeve
30 - Synchro-hub
2. Output shaft 129

Polo 2010 ➤
2.2 Dismantling and assembling output shaft

equipment required

♦ Tube - VW 415 A-

Polo 2010 ➤
♦ -1- Internal puller -

Kukko 21/5-
♦ -4- Counter support -

Kukko 22/1-
Pulling cylindrical roller
bearing out of clutch
housing
– When pulling out,
squeeze together re‐
taining ring -arrow- of
cylindrical roller bear‐
ing, using pliers -C-.
A - Counter support , e.g.
-Kukko 22/1-
B - Internal puller, 30…
37 mm , e.g. -Kukko
21/5-
Pressing cylindrical roller bearing into clutch housing

– Support gearbox housing with tube - VW 415 A- (not visible
here) directly below bearing support.
– When pressing in, squeeze together retaining ring -arrow- for
cylindrical roller bearing using pliers -A-.
– Remove pliers before cylindrical roller bearing is in installation
position. Retaining ring must engage in groove of clutch hous‐
ing.
Dismantling output shaft
When 5th gear wheel -A- cannot be removed by hand.
Pressing off bearing mounting with deep groove ball bearing and
gear wheel for 5th gear -A-
to stop.
When 5th gear wheel can be removed by hand.
2. Output shaft 131

Polo 2010 ➤
Pressing off bearing mounting with deep groove ball bearing

to stop.
Pressing retaining ring -1- out of groove

A - Protective gloves
WARNING
Ensure retaining ring does not spring out uncontrolled.
Pressing off 1st and 2nd gear locking collar and synchro-hub
– Before pressing off, remove retaining ring for synchromeshed
gear for 2nd gear.
– Remove retaining ring -1- and remove gear wheel for 3rd gear
-B- by hand.
– Remove retaining rings -2- and -3- and remove gear wheel for
4th gear -A- by hand.
Assembling output shaft

Polo 2010 ➤
Installation position of 3rd gear and 4th gear

– Install gear wheel for 4th gear -A- on output shaft.
Collar -arrow 1- faces 3rd gear wheel -B-.
– Install retaining rings -2- and -3-.
– Install gear wheel for 3rd gear -B- on output shaft.
Collar -arrow 2- faces gear wheel for 4th gear -A-.
– Install retaining ring -1-.
Checking 1st and 2nd gear inner ring for wear

– Press inner ring onto cone of synchromeshed gear and meas‐
ure gap “a” using a feeler gauge.
Gap “a” Installation dimen‐ Wear limit
sion
1st and 2nd gears 0.60 - 1.25 mm 0.3 mm
Checking 1st and 2nd gear synchro-rings for wear

– Press synchro-ring, outer ring and inner ring onto cone of syn‐
chromeshed gear and measure gap “a” using a feeler gauge.
Gap “a” Installation dimen‐ Wear limit
sion
1st and 2nd gears 1.1 - 1.8 mm 0.5 mm
Installation position of outer ring, inner ring and synchro-ring for

2nd gear
– Place inner ring -A- on 2nd gear synchromeshed gear.
Angled lugs -arrow 1- face outer ring -B-.
– Fit outer ring -B-.
Lugs -arrow 2- engage in notches -arrow 3- of synchromeshed
gear.
– Fit synchro-ring -C-.
Notches -arrow 4- engage in lugs -arrow 1- of inner race -A-.
2. Output shaft 133

Polo 2010 ➤
Dismantling and assembling locking collar and synchro-hub for

1st and 2nd gears
1- Spring
2- Sliding sleeve
3- Synchro-hub
4- Locking piece
After assembly, the groove on the face -arrow A- and the higher
shoulder -arrow B- of synchro-hub face outer splines of the lock‐
ing collar -arrow C-.
Deeper notches -arrow D- for locking pieces in synchro-hub and
notches -arrow E- in locking collar must align.
Assembling locking collar with synchro-hub for 1st and 2nd gears
– Insert locking pieces in deeper cut-outs -arrows- and install
springs offset 120°. Angled end of spring must locate in hollow
locking piece.
Pressing on locking collar and synchro-hub for 1st and 2nd gears
Groove in locking collar for selector fork faces 1st gear and teeth
for reverse gear face 2nd gear.
– Turn synchro-ring so that grooves align with locking pieces.

Polo 2010 ➤
Fitting retaining ring

– Place 1st gear synchro-ring in locking collar/synchro-hub.
Installation position of 1st gear outer ring

Lugs -arrows- face towards reverse gear teeth.
Installation position of 1st gear inner ring -A-

Lugs -arrow 1- engage in notches -arrow 2- in synchro-ring -B-.
Installation position of synchromeshed gear for 1st gear

Higher shoulder -A- faces 2nd gear -B-. Notches in shoulder
-arrows- engage in lugs of outer ring ⇒ page 135 .
2. Output shaft 135

Polo 2010 ➤
Pressing on bearing mounting with deep groove ball bearing

– Heat inner bearing mounting to approx. 100 °C before press‐
ing on.

Polo 2010 ➤
39 – Final drive - differential

1 Renewing flange shaft oil seals with
gearbox installed
1.1 Renewing oil seal for left flange shaft

equipment required
♦ Multi-purpose tool - VW 771-

♦ Extractor hook - VW 771/37-
1.1.1 Removing
– Remove left wheel.
1. Renewing flange shaft oil seals with gearbox installed 137

Polo 2010 ➤
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body front, Assembly overview - noise insulation .
– Unbolt drive shaft from flange shaft.
– Turn steering to left lock.
– If coupling rod -1- is installed, disconnect it from anti-roll bar

⇒ Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
– Remove nuts -arrows- for swivel joint on suspension link ⇒
Running gear, axles, steering; Rep. gr. 40 ; Repairing drive
– Swing wheel bearing housing outwards.
– Pull out left drive shaft between subframe and gearbox.
– When doing this, guide drive shaft into wheel housing and se‐
cure to suspension strut with wire. Take care not to damage
paint on drive shaft in the process.
– Place drip tray under gearbox.
– Unscrew flange shaft securing bolt by screwing 2 bolts into

– Pull out flange shaft with compression spring.
– Pull out flange shaft oil seal using -VW 771- and -VW 771/37- .
138 Rep. gr.39 - Final drive - differential

Polo 2010 ➤
1.1.2 Installing
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
– Insert flange shaft.
– Secure flange shaft with countersunk bolt
⇒ Item 1 (page 143) .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive
shafts .
– Bolt swivel joint onto suspension link ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shafts; Removing and
installing drive shafts .
– Attach coupling rod to anti-roll bar ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shafts; Removing and
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Torque setting for wheel bolts .
– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 74 .
– Mount noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body front, Assembly overview - noise insulation .
1.2 Renewing seal for right flange shaft

Polo 2010 ➤

equipment required
♦ Multi-purpose tool - VW 771-

♦ Extractor hook - VW 771/37-
♦ Drift sleeve - 3158-
1.2.1 Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body front, Assembly overview - noise insulation .
– Turn steering to right to full lock.

Polo 2010 ➤
– Remove drive shaft heat shield, if present -arrows- ⇒ Running

– Unbolt drive shaft from flange shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shaft; Removing and
– Raise drive shaft as high as possible and secure. Take care
not to damage paint on drive shaft in the process.
– Place drip tray under gearbox.
– Unscrew flange shaft securing bolt by screwing 2 bolts into

– Pull out flange shaft with compression spring.
– Remove flange shaft oil seal.
Note
♦ Do not damage sleeve -A-. Otherwise, leaks will occur.

♦ Renew sleeve if damaged ⇒ page 102 and ⇒ page 103 .
1.2.2 Installing
– Drive in new seal to stop, being careful not to cant seal.
– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
– Insert flange shaft.
– Secure flange shaft with countersunk bolt
⇒ Item 1 (page 143) .
– Reconnect drive shaft to flange shaft ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Repairing drive shaft; Removing and

Polo 2010 ➤
– Install drive shaft heat shield, if present -arrows- ⇒ Running

– Check gear oil level and top up to lower edge of oil filler hole
if necessary ⇒ page 74 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Noise insulation .

Polo 2010 ➤
2 Differential
2.1 Assembly overview - differential

Dismantling and assembling differential ⇒ page 145 .
Note
♦ Heat tapered roller bearing inner races to 100 °C before installing.

♦ Always renew both tapered roller bearings together as a set.
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
⇒ page 151 .
1 - Countersunk bolt, 25 Nm
❑ Screw into threaded
piece
⇒ Item 8 (page 143) .
2 - Right flange shaft
3 - Compression spring for
flange shaft
❑ Installed behind flange
shafts
4 - Thrust washer
shoulder towards spring
5 - Tapered ring
taper towards differen‐
tial cage
6 - Retaining ring
❑ Holds tapered ring,
thrust washer and
spring in position when
flange shaft is removed
7 - Large differential bevel gear
❑ Availability ⇒ Electronic
Parts Catalogue (ETKA)

8 - Threaded piece
❑ Availability ⇒ Electronic
Parts Catalogue (ETKA)

9 - Differential pinion pin
❑ Availability ⇒ Electronic Parts Catalogue (ETKA)
❑ To remove and install, first see: removing and installing spring pin, page ⇒ page 150
10 - Small differential bevel gear
2. Differential 143
Polo 2010 ➤
11 - One-piece thrust washer
❑ Coat with gear oil when installing
12 - Left flange shaft
13 - Oil seal for left flange shaft
❑ Renewing with manual gearbox installed ⇒ page 137 .
15 - Tapered roller bearing inner race
❑ Pulling off ⇒ page 149
16 - Differential cage
❑ With final drive gear
17 - Clamping sleeve
❑ For securing differential pinion pin
❑ Removing and installing, as of ⇒ page 150
18 - Tapered roller bearing inner race
❑ Pulling off ⇒ page 150
❑ Pressing out ⇒ page 149 .
20 - Shim
❑ Determining thickness ⇒ page 151
21 - Oil seal for right flange shaft
❑ Renewing with manual gearbox installed ⇒ page 139 .
❑ Bearing seat for tapered roller bearing outer race adapted
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
23 - Clutch housing

Polo 2010 ➤
2.2 Dismantling and assembling differential

equipment required

♦ Press tool - VW 408 A-
♦ Tube - VW 418 A-
2. Differential 145
Polo 2010 ➤
♦ Installing sleeve - VW 455-

♦ Tube - 30 - 14-
♦ Tube - 2040-
♦ Thrust piece - 3002-

Polo 2010 ➤
♦ Counter-hold tool - 3067-

♦ Tube - 3259-
♦ Wheel bearing tube - 3345-
♦ Tapered roller bearing puller - V.A.G 1582-
♦ Grip tool - V.A.G 1582/4-
♦ Internal puller - 1 - Kukko 21/7-
♦ Counter support - 4 - Kukko 22/2-
2. Differential 147
Polo 2010 ➤
♦ Thrust plate - 30 - 205-

♦ Torque wrench - V.A.G 1331- (5…50 Nm)
♦ Grip tool - V.A.G 1582/3-
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing
A - Counter support , e.g. -Kukko 22/2-

Polo 2010 ➤
Pressing tapered roller bearing outer race into gearbox housing

– Support gearbox housing with tube - 3259- directly below
bearing support.
Pulling off tapered roller bearing inner races
Pressing on tapered roller bearing inner races
WARNING
– Heat inner tapered roller bearing race to approx. 100 °C before

pressing on.
– Support inner race on opposite side using installing sleeve -
VW 455- .
Shoulder of installing sleeve - VW 455- faces towards differential
cage.
Pressing tapered roller bearing outer race -A- out of clutch hous‐
ing
– Clamp internal puller securely behind tapered roller bearing
outer race.
2. Differential 149
Polo 2010 ➤
Pressing tapered roller bearing outer race into clutch housing

– Support clutch housing with wheel bearing tube - 3345- di‐
rectly below bearing mounting.
Pulling off tapered roller bearing inner race

– Before fitting extractor, position spacer sleeve - VW 472/2- and
thrust piece - 3002- on differential housing.
Pressing on tapered roller bearing inner race
WARNING
– Heat inner tapered roller bearing race to approx. 100 °C before

pressing on.
Allocation of differential cage for removing and installing spring

pin
– Check hole for spring pin in differential cage.
Bore Length of spring Clamping sleeve
pin (mm)
-A- 24.0 (short Removing Installing
spring pin) ⇒ page 151 ⇒ page 151
-A- and -B- 36.0 (long spring Removing Installing
pin) ⇒ page 151 ⇒ page 151
Through-hole 36.0 (long spring Removing Installing
pin) ⇒ page 151 ⇒ page 151

Polo 2010 ➤
Pressing off differential pinion pin, and shearing off spring pin
When pressed out, spring pin will be sheared off.
– Remove remainder of spring pin from differential cage.
Removing long spring pin to remove differential pinion pin

– Drive spring pin -A- out of hole -arrow- in differential housing
using a 5 mm diameter drift -B-.
Note
If there is no hole -arrow- in the differential cage, shear off the

spring pin ⇒ page 151 .
Installing differential bevel gears

– Lubricate one-piece thrust washer with gear oil and install.
– Install both sun wheels and secure (e.g. with flange shaft).
– Insert both planet pinions offset 180° and pivot into position.
– Press in differential pinion pin (-arrow A-) to first planet pinion.
– Place threaded pieces -arrows B- in sun gears.
Installing spring pin for differential pinion pin

– Align hole in differential pinion pin with hole in differential cage.
– Using a drift, drive in spring pin -1- until a dimension
-a- of 2.5 mm is attained.
• Spring pin -1- must not touch clutch housing.
2.3 Adjusting differential
2. Differential 151
Polo 2010 ➤

equipment required
♦ End dimension plate - VW 385/17-

♦ Universal dial gauge holder - VW 387-

Polo 2010 ➤

♦ Tube - 30 - 14-
♦ Tube - 2040-
♦ Tube - 3259-
♦ Wheel bearing tube - 3345-
♦ Dial gauge
2. Differential 153
Polo 2010 ➤
♦ Thrust plate - 30 - 205-
It is necessary to readjust the differential when the following com‐

ponents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage
or the
♦ Tapered roller bearing of differential
– Pressing tapered roller bearing outer race (gear wheel slide)
into gearbox housing.
Note
Inner and outer tapered roller bearing races are paired. Do not
interchange!
– Press tapered roller bearing outer race (opposite gear wheel)

with no shim into gearbox housing.
– Insert differential in gearbox housing.
– Fit clutch housing and tighten 5 bolts to specified torque

Polo 2010 ➤
– Attach dial gauge and set to “0” with 1 mm preload.

A - 30 mm dial gauge extension
– Set dial gauge to “0” with 1 mm preload.
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 1.50 mm)
2.3.1 Determining shim S2

The specified bearing preload is obtained for S2 by adding a con‐
stant value for preload (0.35 mm) to the measured value.
Example:
Measured value 1.50 mm
+ Preload (constant) 0.35 mm
Thickness of shim S2 = 1.85 mm
– Remove clutch housing and press out tapered roller bearing

outer race -A-.
– Allocate shim(s) using ⇒ Electronic Parts Catalogue “ETKA” .
The various thicknesses make it possible to achieve the exact
shim thickness required.
If the size of shim required is larger than those listed in the ⇒
Electronic Parts Catalogue “ETKA” , insert two shims totalling the
correct figure.
– Insert correct S2 shim (in example 1.85 mm) and press ta‐
pered roller bearing outer race into clutch housing again.
– Fit clutch housing and tighten bolts to specified torque
2. Differential 155

Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U)

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Volkswagen Workshop Manual (6-Speed Manual Gearbox 02U)

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Service

Service Department. Technical Information

2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Injury hazard as a result of automatic engine start in vehicles

1. Safety precautions for vehicles with a start-stop system 1

2.1 Location on gearbox

Manual gearbox 02U -arrow 2-.

Codes and production date of gearbox

The gearbox code is also included on the vehicle data stickers.

2.2 Identification code, assembly allocation, capacities

2 Rep. gr.00 - Technical data Volkswagen Technical Site: https://vwts.ru

The following data can be found in the ⇒ Electronic parts cata‐

The following data can be found in the ⇒ Electronic parts cata‐

Volkswagen Technical Site: https://vwts.ru

3 Overview - power transmission

4 Rep. gr.00 - Technical data

3. Overview - power transmission 5

4 Calculating overall gear ratio “i”

6 Rep. gr.00 - Technical data

5 General repair instructions

5.2 Gaskets and seals

5. General repair instructions 7

5.4 Locking devices

5.5 Nuts and bolts

8 Rep. gr.00 - Technical data

♦ Install only flawless shims.

5.9 Gear wheels

5.10 Synchromeshed gears

5. General repair instructions 9

6.1 Overview of fitting locations - electrical

6.1.1 Overview of fitting locations – electrical components, manual gearbox

1 - Reversing light switch - F4-

6.1.2 Overview of fitting locations – electrical

10 Rep. gr.00 - Technical data

Clutch pedal switch - F36-

1.1 Overview - clutch actuation

I - Assembly overview - pedal

12 Rep. gr.30 - Clutch

1.2 Assembly overview - pedal cluster

1. Repairing clutch mechanism 13

Removing and installing extension spring

14 Rep. gr.30 - Clutch

1.3 Removing, installing and adjusting

1.3.1 Removing clutch pedal switch

1.3.2 Installing clutch pedal switch

-B- = »with light dome« on • Plunger is not allowed to be

• Grease plunger head.

Clutch pedal switch is installed from plenum chamber bulkhead.

1. Repairing clutch mechanism 15

1.4 Removing and installing mounting bracket with master cylinder

Special tools and workshop

♦ Hose clamp - 3094-

16 Rep. gr.30 - Clutch

An insulation mat is installed in conjunction with some engines.

♦ During the following work, ensure that no brake fluid lands on

– Clamp off supply hose to master cylinder using hose clamp -

1. Repairing clutch mechanism 17

Vehicles with start/stop system:

When performing work in the footwell, put cloths on the carpet to

– Remove driver side trim ⇒ General body repairs, interior; Rep.

– If fitted, remove crash bar -arrow-.