Volkswagen Workshop Manual (6-Speed Manual Gearbox 0A8)

Service
Workshop Manual
Polo 2014 ➤
6-speed manual gearbox 0A8
Edition 03.2017
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 2014 ➤
6-speed manual gearbox 0A8 - Edition 03.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Clutch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Overview of fitting locations – clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Assembly overview - clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 Removing and installing bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.6 Checking clutch master cylinder and clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.8 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.9 Removing and installing extension spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.10 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.11 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.12 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.13 Removing and installing bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.14 Removing and installing lines for clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.15 Removing and installing clutch slave cylinder together with release bearing . . . . . . . . . . . . 34
1.16 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.17 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1 Assembly overview - clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2 Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1 Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Installation position - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.2 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3 Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.4 Removing and installing gear knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.6 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.7 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.8 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.1 Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2 Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3 Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Contents i
Polo 2014 ➤
3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.1 Distinguishing between different manual gearbox types when filling oil . . . . . . . . . . . . . . . . 99
5.2 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6 Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.1 Schematic overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.2 Assembly overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.3 Assembly overview - gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . . . . 106
7.4 Assembly overview - selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.5 Assembly overview - shafts, differential, selector mechanism . . . . . . . . . . . . . . . . . . . . . . 109
7.6 Assembly overview - selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.7 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.8 Removing and installing selector unit with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . 113
7.9 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8 Gearbox housing, clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.1 Assembly overview - gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.2 Assembly overview - clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
8.3 Repairing gearbox housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
8.4 Repairing clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 Assembly overview - input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 Assembly overview - output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.2 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.3 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

1 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.2 Renewing left oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.3 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.1 Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.3 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
ii Contents
Polo 2014 ➤
00 – Technical data
1 Safety information
(VRL010194; Edition 03.2017)
⇒ “1.1 Safety precautions when working on vehicles with a start/
stop system”, page 1
1.1 Safety precautions when working on ve‐

hicles with a start/stop system
WARNING
Injury hazard as a result of automatic engine start in vehicles

with start/stop system.
♦ Deactivate the start/stop system when working on vehicle.
Switch off ignition.
♦ Switch on the ignition briefly only if required.
1. Safety information 1
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2 Identification
⇒ “2.1 Gearbox identification”, page 2
2.1 Gearbox identification

Code letters and production date -arrow 1- manual gearbox
0A8-arrow 2-
Manual gearbox 0A8 -arrow 2-.
Codes and production date of gearbox -arrow-

Example: NJU 28 05 2
I I I I
I I I I
Identification Day Month Year (2012)
code of manufacture
Additional data provide information about the production facility.
Note
The gearbox code also appears on the vehicle identification

plates.
2 Rep. gr.00 - Technical data

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3 Technical data
⇒ “3.1 Allocation gearbox - engine”, page 3 .
⇒ “3.2 Capacities”, page 3 .
⇒ “3.3 Calculation of gear ratios”, page 3 .
3.1 Allocation gearbox - engine

Manual gearbox 6-speed, 0A8
Identification code NJU QDG QQR
Manufactured from 05.14 11.14 11.14
to 11.14
Allocation Engine 1.4 l - 110 kW 1.8 l - 136 kW 1.8 l - 141 kW
Ratio: Z2 : Z1 Final drive I 69 : 20 = 3.450 70 : 19 = 3.684 68 : 21 = 3.238
Final drive II 69 : 25 = 2.760 70 : 24 = 2.917 68 : 26 = 2.615
Drive shaft flange diameter 107 mm 107 mm 107 mm
• Final drive I for 1st to 4th gear
• Final drive II for 5th, 6th and reverse gear
Glean following data from ⇒ Electronic parts catalogue (ETKA) :
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation
3.2 Capacities
⇒ “5.1 Distinguishing between different manual gearbox types
when filling oil”, page 99
⇒ “3.2.1 Capacity, manual gearbox”, page 3
3.2.1 Capacity, manual gearbox

Capacity of manual gearbox (gear‐ 2.30 litres
box completely dismantled)
Capacity of manual gearbox (gear‐ 2.15 litres
box partially dismantled)
3.3 Calculation of gear ratios

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
Volkswagen Technical Site: https://vwts.ru 3. Technical data 3

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4 Overview - power transmission

Designation:
-Arrows- point in direction of travel.
1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft for 5th, 6th and
reverse gears
6 - Output shaft for 1st to 4th
gear
7 - Differential
Ratio
-Arrows- point in direction of travel.

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I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive
4. Overview - power transmission 5

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5 Electrical components
⇒ “5.1 Overview of fitting locations - electrical components”, page
6
5.1 Overview of fitting locations - electrical

components
⇒ “5.1.1 Overview of fitting locations – electrical components,
manual gearbox”, page 6
⇒ “5.1.2 Overview of fitting locations – electrical components,
clutch mechanism”, page 6
5.1.1 Overview of fitting locations – electrical components, manual gearbox
1 - Gearbox neutral position

sender - G701-
❑ Fitting location: in area
of selector unit beneath
angled rod for securing
selector shaft
❑ Removing and installing
⇒ page 106
2 - Reversing light switch - F4-
❑ Fitting location: in area
of selector unit beneath
angled rod for securing
selector shaft
⇒ page 106
5.1.2 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 and installing clutch position sender - G476-
⇒ page 29 .

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6 Repair notes
⇒ “6.1 General repair instructions”, page 7
6.1 General repair instructions

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.
Special tool
For a complete list of special tools used in this workshop manual,
see ⇒ Electronic parts catalogue (ETKA) .
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.
♦ Allocate bolts and other components using the ⇒ Electronic
parts catalogue (ETKA) .
♦ If the gearbox is repaired, fill with gear oil.
Gaskets and seals
After removing gaskets and seals, always inspect contact surfa‐
ces of housing and shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing radial oil seals, half-fill space between sealing
lips with sealing grease -arrow-.
♦ For grease allocation, refer to ⇒ Electronic parts catalogue
(ETKA) .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Lightly oil O-rings before installing; this prevents the rings be‐
ing crushed when inserted.
Sealant
♦ Thoroughly clean housing joint surfaces before applying seal‐
ant .
♦ Apply sealant uniformly and not too thickly.
♦ Allocation ⇒ Electronic parts catalogue (ETKA) .
♦ Breather holes must remain free of sealant .
6. Repair notes 7
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Locking devices
♦ Renew retaining rings.

♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot must be in line
with direction of force.
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.
♦ Renew self-locking bolts and nuts after each removal.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Check pitch of thread, to ensure correct thread chaser is used
to clean threads and to ensure the threads are not damaged.
Bearings
♦ Lubricate all bearings with gear oil before installing.
♦ 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 inner races to about 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.

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Shims
♦ Measure shims at several points with a micrometer. The var‐
ious tolerances make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
Synchro-rings
♦ Do not interchange. 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 the cone of the synchromeshed gear for »scoring« and
»signs of abnormal wear«.
♦ Moisten synchromesh mechanism with gear oil before instal‐
ling.
Gears and synchro-hubs
♦ Clean before pressing on. Heat to a maximum of 100°C using
inductive heater - VAS 6414- .
♦ Observe installation position
Synchromeshed gears
♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.
Clutch operation
Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and connecting battery .
When reconnecting battery, refer to ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Clutch
♦ Ensure that the pressure plate does not cant: loosen and tight‐
en bolts diagonally and in several gradual stages.
♦ In order to reduce the smell of a burned clutch, the clutch
housing as well as the stopping face of the flywheel must be
thoroughly cleaned with a cloth.
6. Repair notes 9
Polo 2014 ➤
30 – Clutch
1 Clutch operation
⇒ “1.1 Overview of fitting locations – clutch mechanism”,
page 10
⇒ “1.2 Assembly overview - pedal cluster”, page 12
⇒ page 14
⇒ “1.3 Assembly overview - clutch hydraulics”, page 14
⇒ “1.4 Assembly overview - clutch release mechanism”,
page 18
⇒ “1.5 Removing and installing bearing bush”, page 19
⇒ “1.6 Checking clutch master cylinder and clutch slave cylinder”,
page 20
⇒ “1.7 Removing and installing clutch position sender G476 ”,
page 20
⇒ “1.8 Removing and installing over-centre spring”, page 22
⇒ “1.9 Removing and installing extension spring”, page 23
⇒ “1.10 Removing and installing clutch pedal”, page 23
⇒ “1.11 Removing and installing mounting bracket”, page 25
⇒ “1.12 Removing and installing clutch master cylinder”,
page 29
⇒ “1.13 Removing and installing bleeder”, page 30
⇒ “1.14 Removing and installing lines for clutch mechanism”,
page 31
⇒ “1.15 Removing and installing clutch slave cylinder together
with release bearing”, page 34
⇒ “1.16 Bleeding clutch mechanism”, page 35
⇒ “1.17 Repairing clutch release mechanism”, page 36
1.1 Overview of fitting locations – clutch mechanism
10 Rep. gr.30 - Clutch

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I-
⇒ “1.2 Assembly overview -
pedal cluster”, page 12
II -
⇒ “1.3.1 Assembly overview -
clutch hydraulics, left-hand
drive”, page 14
III -
⇒ “1.3.2 Assembly overview -
clutch hydraulics, right-hand
drive”, page 16
1. Clutch operation 11
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1.2 Assembly overview - pedal cluster
1 - Clutch pedal
⇒ page 23
❑ Do not grease
2 - Bearing bush
⇒ page 19
❑ Do not grease
3 - Clutch master cylinder
⇒ page 29
4 - Clip
❑ To remove pipe/hose
line, pull out clip to stop
❑ Can be pressed in as far
as stop before fitting line
5 - Seal
❑ Self-adhesive
❑ Renew after removing
the clutch master cylin‐
der.
❑ Glue onto clutch master
cylinder
6 - Clutch position sender -
G476-
❑ Can be checked using
⇒ Vehicle diagnostic
tester in Guided Fault
Finding mode
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
⇒ page 20
7 - Pivot pin
❑ Renew after removal
❑ Do not grease
8 - Bulkhead
❑ With studs for securing mounting bracket and master cylinder
9 - Bush
❑ For upper mounting hole in mounting bracket
❑ Bushes for lower mounting holes in mounting bracket are located in master cylinder
10 - Hexagon nut
❑ For securing mounting bracket and clutch master cylinder to plenum chamber bulkhead
❑ Qty. 3
❑ Self-locking
❑ 25 Nm
11 - Crash bar
❑ Secured to module carrier

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❑ Allocate according to ⇒ Electronic parts catalogue (ETKA)
12 - Hexagon nut
❑ For crash bar on module carrier
❑ 20 Nm
13 - Mounting bracket
❑ For clutch pedal
❑ Removing and installing ⇒ page 25
❑ Using drift - VW 207- drive bushes for the studs used to fasten the mounting bracket onto the bulkhead,
into the holes in the mounting bracket
14 - Buffer stop
15 - Over-centre spring or extension spring
❑ Grease support on mounting bracket
❑ For grease allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
❑ Installed depending on version.
❑ Different versions exist; for correct version refer to ⇒ Electronic parts catalogue (ETKA)
❑ Removing and installing over-centre spring ⇒ page 22
❑ Removal and installation of extension spring are identical to removal and installation of over-centre spring
⇒ page 22
16 - Bearing bush
❑ Do not grease
17 - Bearing mounting
❑ For plunger/clutch master cylinder
❑ Do not grease
18 - Cap
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1.3 Assembly overview - clutch hydraulics

⇒ “1.3.1 Assembly overview - clutch hydraulics, left-hand drive”,
page 14
⇒ “1.3.2 Assembly overview - clutch hydraulics, right-hand drive”,
page 16
1.3.1 Assembly overview - clutch hydraulics, left-hand drive
1 - Clutch slave cylinder

❑ Can be renewed only
with gearbox removed
⇒ page 34
2 - Bleeder
3 - Seal/O-ring
❑ Renew if damaged
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 31
4 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line
5 - Bleeder valve
❑ Bleeding clutch mecha‐
nism ⇒ page 35
❑ With hex: specified tor‐
que 4.5 Nm
❑ Flattened on both sides:
close as far as stop
6 - Dust cap
7 - Clip
8 - Supply hose
9 - Brake fluid reservoir
10 - Seals
❑ Must be fitted in supply hose
❑ If damaged, renew together with supply hose
12 - Clip
Is pulled out in direction of front end ⇒ Item 4 (page 12)
❑ To remove pipe/hose line, pull out clip to stop

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❑ Can be pressed in as far as stop before fitting line
13 - Seal/O-ring
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 31
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
14 - Pipe/hose line
❑ Appearance may be different from that illustrated
15 - Bracket
❑ Secured to body
❑ For pipe/hose line
16 - Seal/O-ring
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1.3.2 Assembly overview - clutch hydraulics, right-hand drive
1 - Bleeder
2 - Seal/O-ring
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 31
3 - Clutch slave cylinder
❑ Can be renewed only
with gearbox removed
⇒ page 34
4 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose line
5 - Bleeder valve
❑ Bleeding clutch mecha‐
nism ⇒ page 35
❑ With hex: specified tor‐
que 4.5 Nm
❑ Flattened on both sides:
close as far as stop
6 - Dust cap
7 - Clip
8 - Seal/O-ring
9 - Brake fluid reservoir
10 - Seals
❑ Must be fitted in supply hose
❑ If damaged, renew together with supply hose
11 - Supply hose
13 - Clip
❑ Is pulled out in direction of front end

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❑ To remove pipe/hose line, pull out clip to stop
❑ Can be pressed in as far as stop before fitting line
14 - Brake lines
15 - Bracket
❑ Secured to body
❑ For brake lines and pipe/hose line
16 - Pipe/hose line
❑ Appearance may be different from that illustrated
17 - Bracket
❑ Secured to body
❑ For pipe/hose line
18 - Seal/O-ring
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1.4 Assembly overview - clutch release mechanism
1 - Clutch slave cylinder with

release bearing
❑ Are one unit and can be
renewed together only
❑ Do not wash out bear‐
ing; wipe only
❑ Renew noisy bearings
together with clutch
slave cylinder
❑ For some clutch slave
cylinders, divided sup‐
ply line ⇒ page 37
⇒ page 34
2 - Bolt
❑ Qty. 3
❑ Take account of the
thread pitch of bolt for
cleaning threaded hole
in clutch housing.
Note
Use compressed air to clean hole. If

necessary, screw a clean, removed
bolt into and out of the hole to loosen
locking fluid residue.
❑ Carefully tighten diago‐
nally in small steps so
that the fastening lugs of
the clutch slave cylinder
do not break off.
❑ 12 Nm for clutch slave cylinders made of metal (without locking fluid)
❑ 15 Nm for clutch slave cylinders made of plastic (with locking fluid)
3 - Clip
❑ Pull clip out to stop to remove or install pipe line
❑ Push on until clip engages audibly.
4 - Pipe
❑ To clutch slave cylinder.
5 - O-ring

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Release bearing with additional plastic washer

Identifying feature: grooves -arrow- on the plastic washer.
For release bearing with additional plastic disc only: tips of dia‐
phragm springs on pressure plate (-arrows-), slightly lower overall
height
• Release bearing with additional plastic disc and clutch pres‐
sure plate with tips of diaphragm springs of slightly lower
overall height must only be installed together.
1.5 Removing and installing bearing bush

Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Compress catches -arrows- and take out pin -1- towards right
side.
– Pull clutch pedal into passenger compartment as far as stop.
– Remove over-centre spring/extension spring.
– Turn plunger of clutch master cylinder so that recesses -1- or

marking -2- become visible.
Ensure that recesses -1- and marking -2- point in same direction.
– Remove bearing bush -A- from recesses -1-.
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Installing
– Turn plunger of clutch master cylinder so that recesses -1- or
marking -2- become visible.
Ensure that recesses -1- and marking -2- point in same direction.
– Fit and swivel bearing bush -A- into recesses -1-.
– Install over-centre spring/extension spring ⇒ page 22 , and
connect plunger/clutch master cylinder to clutch pedal.
– Use new pivot pin.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
1.6 Checking clutch master cylinder and

clutch slave cylinder
Carry out Guided Fault Finding using ⇒ Vehicle diagnostic
tester before renewing clutch master cylinder due to suspected
fault.
1.7 Removing and installing clutch position

sender - G476-
Special tools and workshop equipment required
♦ Hook - 3438-
Removing
LHD vehicles
– Unclip engine control unit from bracket on plenum chamber
bulkhead without disconnecting electrical connector, and lay
it to one side ⇒ Rep. gr. 24 ; Engine control unit .
RHD vehicles
In some vehicles, master cylinder is located behind a line for air
conditioning system -arrow-.

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An insulation mat is installed in conjunction with some engines.

Appearance may be different from that illustrated.
– Remove insulation mat. Note item -1 to 4-.
Continued for all

– Unclip clutch position sender - G476- on master cylinder
-arrow A- and -arrow B-.
– Remove clutch position sender - G476- from master cylinder,
and disconnect connector.
Installing
– Insert clutch position sender - G476- into master cylinder with
electrical connector connected. Push it in as far as stop.
• Clutch position sender - G476- must clip in -arrow A-.
– To check, pull on clutch position sender - G476- -arrow B-.
– Disregard items -1, 2 and 3-.
– If fitted, fold insulation mat in the sequence -1, 2, 3- around

lines.
– Secure insulation mat with lock washer -4-.
LHD vehicles
– Clip engine control unit with connector connected into bracket
on plenum chamber bulkhead ⇒ Rep. gr. 24 ; Engine control
unit .
Polo 2014 ➤
1.8 Removing and installing over-centre

spring
Removing
– Move driver seat as far back as possible.
– Move steering wheel to uppermost position using the entire
range of adjustment of the steering column.
– Compress catches -arrows- and pull out pivot pin -1- for plung‐
er/clutch master cylinder towards right side.
– Pull clutch pedal into passenger compartment as far as stop.
– Remove over-centre spring.
Installing
Install in reverse order of removal, observing the following:
• Receptacle -arrow- for mounting pin of clutch pedal must be
vertical.
– Insert over-centre spring from side and from below, adjacent

to plunger of master cylinder and adjacent to clutch pedal, into
support -A- in mounting bracket.
– Now position over-centre spring on mounting lug of clutch

pedal -arrow-.

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Note
♦ The over-centre spring must be located directly in the mount‐

ing -arrow 1- in the bearing bracket to be fitted correctly on the
clutch pedal -arrow 2- (⇒ see also previous illustration).
♦ Otherwise, it will not be possible to install the pivot pin -1- for
the plunger/clutch master cylinder (⇒ next illustration).
– Press clutch pedal in operating position, and push new pivot

pin -1- for plunger/clutch master cylinder through to stop.
• Make sure that fasteners -arrows- of pivot pin -1- engage.
1.9 Removing and installing extension

spring
Removal and installation of extension spring are identical to re‐
moval and installation of over-centre spring ⇒ page 22 .
1.10 Removing and installing clutch pedal

⇒ “1.10.1 Removing and installing clutch pedal, LHD”,
page 23
⇒ “1.10.2 Removing and installing clutch pedal, RHD”,
page 24
1.10.1 Removing and installing clutch pedal,

LHD
Removing
– Move driver seat as far back as possible.
– Move steering wheel to uppermost position using the entire
range of adjustment of the steering column.
– Remove over-centre spring/extension spring ⇒ page 22 .
– If installed in area of mounting bracket: remove onboard sup‐
ply control unit - J519- ⇒ Electrical system; Rep. gr. 97 ;
Control units; Removing and installing onboard supply control
unit - J519- .
Polo 2014 ➤
Remove bearing shaft for clutch pedal:

– Break off both locking devices -A- using a screwdriver -1-.
Locking devices -A- will be irreparably damaged.
-1- = 10 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.
Installing
• Renew pivot pin after removing.
– Depress clutch pedal slightly and push new pivot pin through
to stop.
– Turn pivot pin to right to stop, -direction of arrow-.
• Locking devices -A- must audibly engage.
– Install over-centre spring/extension spring ⇒ page 22 .
– If removed beforehand: install onboard supply control unit -
J519- ⇒ Electrical system; Rep. gr. 97 ; Control units; Re‐
moving and installing onboard supply control unit - J519- .
1.10.2 Removing and installing clutch pedal,

RHD
Removing
– Remove mounting bracket ⇒ page 25 .

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– Compress fasteners -arrows-, and pull pivot pin -1- for plunger/
clutch master cylinder off towards right (shown in illustration
with mounting bracket installed).
– Pull clutch pedal as far as stop.
– Remove over-centre spring/return spring.
Remove bearing shaft for clutch pedal:
– Break off both locking devices -A- using a screwdriver -1-.

Locking devices -A- will be irreparably damaged.

• 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.
Installing
• Renew pivot pin after removing.
– Push new pivot pin through to stop.
– Turn pivot pin to right to stop, -direction of arrow-.
• Locking devices -A- must audibly engage.
– Install over-centre spring/extension spring ⇒ page 22 .
– Install mounting bracket ⇒ page 25 .
1.11 Removing and installing mounting

bracket
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♦ Hose clamps, up to 25 mm - 3094-
♦ Torque wrench - V.A.G 1331-
♦ Sealing tool - T10249-
Removing
LHD vehicles

Polo 2014 ➤
RHD vehicles

Continued for all
– Remove clutch position sender - G476- (without disconnecting
connector) from master cylinder ⇒ page 20 .
– Clamp off supply hose -1- to clutch master cylinder with a hose
clamp - 3094- .
Note
♦ On RHD vehicles, the frequency modulator (round component

beneath clip -2-) is not located directly at the clutch master
cylinder ⇒ page 16 .
♦ Clamping off the supply hose with the hose clamp - 3094- will
cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp - 3094- , the supply hose must
be returned to its original shape.
Caution
Risk of leaking brake fluid.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Lay a lint-free cloth under clutch master cylinder.
Polo 2014 ➤
– In addition, for disconnecting, supply hose can be sealed with

sealing tool - T10249/1- .
– Pull off supply hose -1- (⇒ previous illustration).
– Pull clip -2- for pipe/hose line all way out (⇒ previous illustra‐
tion), and pull off pipe/hose line ⇒ page 31 .
– Seal openings.
– Unscrew nut -2-, detach crash bar -1-, and push to one side.
– Remove following components if installed in area of mounting
bracket:
Onboard supply control unit - J519- ⇒ Electrical system; Rep. gr.
97 ; Control units; Removing and installing onboard supply control
unit - J519-
Footwell vent on driver side ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview – air duct and air distribution in
passenger compartment
– Unscrew nuts -1- and -2-.

– Remove mounting bracket -3-.
Installing
– Renew self-locking nuts and seal for clutch master cylinder
after removing.
– Fit crash bar -1-, and tighten nut -2-.

– If removed beforehand, reinstall following components:
Onboard supply control unit - J519- ⇒ Electrical system; Rep. gr.
97 ; Control units; Removing and installing onboard supply control
unit - J519-
Footwell vent on driver side ⇒ Heating, air conditioning; Rep. gr.
87 ; Air duct; Assembly overview – air duct and air distribution in
passenger compartment
– Insert clutch position sender - G476- into master cylinder with
electrical connector connected. Push it in as far as stop
⇒ page 20 .

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– Connect pipe/hose line to connection ⇒ page 31 .

Clip -2- is pushed in.
– Connect supply hose -1- at clutch master cylinder.
• After removing the hose clamp - 3094- , the supply hose must
LHD vehicles
unit .
RHD vehicles
The frequency modulator (⇒ round component beneath clip -2- in

previous illustration) is not located directly at the clutch master
lines.
Continued for all
– Bleed clutch mechanism ⇒ page 35 .
– Install and/or connect battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Specified torques
♦ For securing mounting bracket to plenum chamber bulkhead
⇒ page 12
♦ Crash bar to module carrier ⇒ page 12
1.12 Removing and installing clutch master

cylinder
Note
♦ Before replacing the clutch master cylinder due a suspected

defect, use Guided Fault Finding ⇒ Vehicle diagnostic
tester.
♦ When performing work in the footwell, put cloths on the floor
covering to protect it from possible brake fluid spills.
Removing
– Remove mounting bracket with clutch master cylinder
⇒ page 25 .
Polo 2014 ➤
– Compress fasteners on pivot pin -1- for plunger/clutch master

cylinder -arrows- (shown in illustration with mounting bracket
installed).
– Pull pivot pin for plunger/clutch master cylinder in direction of

-arrow A- out of clutch pedal.
Clutch master cylinder is engaged in mounting bracket by means
of catches -arrows B-.
– Release locking tabs -arrows B- from clutch master cylinder,
and forcefully pull clutch master cylinder out of mounting
bracket.
Illustration shows only 2 of 4 locking tabs -arrows B-.
Installing
• Renew pivot pin -arrow A- after removing.
• Pivot pin -arrow A- must audibly engage in clutch pedal.
– Ensure proper engagement by carefully pulling pivot pin.
– Engage clutch master cylinder in mounting bracket
-arrows B-.
– Ensure proper engagement by carefully pulling clutch master
cylinder.
– Install mounting bracket ⇒ page 25 .
1.13 Removing and installing bleeder

Removing pipe/hose assembly or pipe -4- from and installing on
bleeder -1-.
– Release securing clip -2- with a screwdriver or pointed object
to remove. Pull pipe/hose line or pipe -4- off bleeder -1-.
– To install pipe/hose line or pipe, push onto bleeder connection
with O-ring -3- until securing clip engages audibly.
– Test line by tugging on it.

Polo 2014 ➤
Disconnecting and connecting lines for clutch hydraulics

Disconnecting
– Release clip -3- with a screwdriver, and disconnect pipe/hose
line -1- from connection -4-.
Connecting
Note
♦ It is also possible to install an O-ring instead of the seal -2-

⇒ page 31 .
♦ Renew seal -2- if damaged.
– Press pipe/hose line -1- into connection -4- until clip -3- en‐
gages audibly.
– Test pipe/hose line by tugging on it.
Seals and O-rings for pipe/hose line or pipe line

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.
Removing bleeder -4- from and installing on clutch slave cylinder

– Release securing clip -2- with a screwdriver or pointed object
to remove. Pull bleeder -4- off clutch slave cylinder -1-.
– To install, check O-ring -3- on clutch slave cylinder. Press
bleeder onto clutch slave cylinder connection until securing
clip -2- engages audibly.
– Check by pulling on bleeder.
1.14 Removing and installing lines for clutch

mechanism
Polo 2014 ➤
♦ Hose clamps, up to 25 mm - 3094-
Removing
– Remove complete air filter housing if it prevents access to the
lines for clutch mechanism ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing .
Battery in engine compartment
– Remove battery tray, battery and battery cover ⇒ Electrical
system; Rep. gr. 27 ; Battery; Removing and installing battery .
LHD vehicles
RHD vehicles

Continued for all
Caution
Risk of leaking brake fluid.

♦ During the following work, ensure that no brake fluid lands
on longitudinal member or gearbox. If this does happen,
clean the affected areas thoroughly.
♦ Lay a lint-free cloth under clutch master cylinder.

Polo 2014 ➤
– Clamp off supply hose -1- to clutch master cylinder with a hose
clamp - 3094- .
Note
♦ On RHD vehicles, the frequency modulator (round component

beneath clip -2-) is not located directly at the clutch master
♦ Clamping off the supply hose with the hose clamp - 3094- will
cause a permanent deformation.
♦ However, this does not damage the supply hose.
♦ After removing the hose clamp - 3094- , the supply hose must
– Pull out clip for pipe/hose line -2- as far as stop, and detach
pipe/hose line.
– Seal openings.
– Pull out clip -arrow- as far as stop and pull pipe/hose line -A-
off bleeder.
-Item B- can be disregarded.
– Seal off open lines and connections if necessary with clean
plugs from engine bung set - VAS 6122- .
– Move clear pipe/hose line, and detach it.
Installing
– Push pipe/hose line or pipe line -1- with O-ring -2- onto con‐
nection of clutch master cylinder -4- until securing clip -3-
engages audibly.
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– Push line with O-ring -3- onto bleeder connection until secur‐
ing clip engages audibly.
• After removing the hose clamp - 3094- , the supply hose must
LHD vehicles
unit .
RHD vehicles
lines.
Continued for all
– Install battery tray, battery and battery cover ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Removing and installing battery .
Continued for all
– Install complete air filter housing ⇒ Rep. gr. 24 ; Air filter;
Removing and installing air filter housing .
1.15 Removing and installing clutch slave

cylinder together with release bearing
Note
♦ Clutch slave cylinder and release bearing are a single com‐

ponent and can be renewed only together.
♦ Take account of the thread pitch of securing bolts of clutch
slave cylinder for cleaning threaded hole in clutch housing.

Polo 2014 ➤
Removing
• Gearbox has been removed.
– Release securing clip -2- with a screwdriver or pointed object.
Pull bleeder -4- off clutch slave cylinder -1-.
– Unscrew bolts -arrows-.

– Remove clutch slave cylinder together with release bearing
-A-.
Installing
• The securing bolts for the clutch slave cylinder must be tight‐
ened only in small stages.
Otherwise, the tabs with the bolt holes may break off.
– Check O-ring -3- on clutch slave cylinder for damage.

– Press in bleeder -4- on clutch slave cylinder connection -1-
until securing clip -2- engages audibly.
– Check by pulling on bleeder.
– Install gearbox.
Specified torques
♦ Clutch slave cylinder with clutch release bearing to gearbox
⇒ page 18 .
1.16 Bleeding clutch mechanism

♦ Brake filling and bleeding equipment - VAS 5234- or
Polo 2014 ➤
Note
♦ The clutch system must always be bled after performing work

on the hydraulic clutch mechanism.
♦ During the following work, ensure that no brake fluid lands on
longitudinal member or gearbox.
♦ Prefilling system is not necessary!
♦ Before bleeding, fill brake fluid reservoir up to “max” marking
with brake fluid.
♦ Clutch pedal is at rest position, is not being depressed.
♦ Brake fluid: Allocation ⇒ Electronic parts catalogue (ETKA) .
– Remove complete air filter housing ⇒ Rep. gr. 24 ; Air filter;

– Connect brake filling and bleeding device - VAS 5234- .
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.
– Connect bleeder hose -A- to bleeder -arrow-.
– Switch on brake filling and bleeding equipment .
– Pressurise system to 2 bar.
– Open bleeder valve by about 1/4 turn.
– Move clutch pedal 15 to 20 times quickly by hand from stop to

stop.
– Close bleeder valve and switch off brake filling and bleeding
equipment .
♦ Bleeder valve with hex: specified torque 4.5 Nm
♦ Bleeder valve flattened on both sides: close as far as stop
– After completing bleeding procedure, when the pressure of
2 bar is released, operate clutch pedal ten more times by foot.
1.17 Repairing clutch release mechanism

♦ Grease for splines

Polo 2014 ➤

(ETKA) .
– Remove and install clutch slave cylinder with clutch release
bearing -A- -arrows-.
Clutch slave cylinder -A- with divided supply line

The supply line for some clutch slave cylinders is divided in the
area of the -arrow-.
Allocation ⇒ Electronic parts catalogue (ETKA)
Specified torques
♦ Clutch slave cylinder with clutch release bearing to gearbox
⇒ page 18 .
Polo 2014 ➤
2 Clutch
⇒ “2.1 Assembly overview - clutch”, page 38
⇒ “2.2 Removing and installing clutch”, page 41
2.1 Assembly overview - clutch

⇒ “2.1.1 Assembly overview - clutch in conjunction with Sachs
dual-mass flywheel”, page 38
⇒ “2.1.2 Assembly overview - clutch in conjunction with LuK dual-
mass flywheel”, page 39
⇒ “2.1.3 Assembly overview - clutch with simple flywheel”,
page 40
2.1.1 Assembly overview - clutch in conjunction with Sachs dual-mass flywheel
1 - Dual-mass flywheel
⇒ Rep. gr. 13 ; Cylinder
block (gearbox end);
Removing and installing
flywheel .
❑ Ensure that centring
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
❑ Renew only together
with pressure plate
⇒ page 41
❑ Installation position
⇒ page 44
3 - Pressure plate
❑ With adjusting mecha‐
nism
with clutch plate.
⇒ page 41
❑ Check ends of dia‐
phragm spring
⇒ page 44
❑ Check spring connec‐
tions and riveted con‐
nections ⇒ page 44 .
❑ Release bearing with additional plastic disc ⇒ page 19 , pressure plate is matched accordingly
⇒ page 19
4 - Bolt
❑ Loosen or tighten diagonally in small steps

Polo 2014 ➤
❑ M 6: 13 Nm
❑ M 7: 20 Nm
2.1.2 Assembly overview - clutch in conjunction with LuK dual-mass flywheel
1 - Dual-mass flywheel
flywheel .
pins fit tightly
❑ Contact surface for
clutch lining must be
free of grooves, oil and
grease
2 - Clutch plate
⇒ page 45
with SAC pressure
plate.
❑ Installation position:
⇒ page 47
3 - SAC pressure plate
❑ SAC means “self-ad‐
justing clutch”.
with clutch plate.
⇒ page 45
phragm spring
⇒ page 48
tions and riveted connections ⇒ page 48 .
❑ Release bearing with additional plastic disc ⇒ page 19 , pressure plate is matched accordingly
⇒ page 19
4 - Bolt
❑ Loosen or tighten diagonally in small steps
❑ M 6: 13 Nm
❑ M 7: 20 Nm
2. Clutch 39
Polo 2014 ➤
2.1.3 Assembly overview - clutch with simple flywheel
1 - Flywheel
flywheel .
pins fit tightly
❑ Keep contact surface for
clutch lining free of
grooves, oil and grease.
2 - Clutch plate
❑ Centring ⇒ page 50
3 - Pressure plate
⇒ page 50
phragm spring
⇒ page 52
tions and riveted con‐
nections ⇒ page 52 .
4 - Bolt
❑ Loosen or tighten diag‐
onally in small steps
❑ M 6: 13 Nm
❑ M 7: 20 Nm

Polo 2014 ➤
2.2 Removing and installing clutch

⇒ “2.2.1 Removing and installing clutch in conjunction with Sachs
⇒ “2.2.2 Removing and installing clutch in conjunction with LuK
⇒ “2.2.3 Removing and installing clutch in connection with simple
flywheel”, page 50
2.2.1 Removing and installing clutch in conjunction with Sachs dual-mass fly‐
wheel
Special tools and workshop

equipment required
♦ Counter-hold tool - 3067-

♦ Centring mandrel - T10097-
(ETKA) .
2. Clutch 41
Polo 2014 ➤
♦ For engines having a crankshaft of smaller diameter or having

needle bearings in the crankshaft - ⇒ page 45 centring man‐
drel - 3176-

Polo 2014 ➤
Removing
• Gearbox is removed.
– Use counter-hold tool - 3067- to loosen bolts.
To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:
– Loosen all bolts in small steps and diagonally.
• As bolts are removed, stop -2- with pin -1- must loosen.
– If stop does not loosen, push pin in direction of dual-mass fly‐
wheel.
– Remove pressure plate and clutch plate.
Installing
Note
♦ Select clutch pressure plate and pressure plate according to

engine code and ⇒ Electronic parts catalogue (ETKA) .
♦ Clean splines of drive shaft and, if the clutch plate has been
used, clean the splines of the hub. Remove corrosion and ap‐
ply a very thin coat of clutch plate spline grease to splines.
Then, move the clutch plate back and forth on the drive shaft
until the hub moves easily on the shaft. Remove excess
grease.
♦ Clutch pressure plates are protected against corrosion and
greased. With the exception of the friction surface for the
clutch plate, the clutch pressure plate must not be cleaned.
Service life of clutch will otherwise be shortened considerably.
♦ The friction surface of the clutch pressure plate and the fly‐
wheel must be cleaned (degreased) thoroughly.
♦ If the clutch has burnt out, thoroughly clean the gearbox hous‐
ing in the clutch area and the engine facing the gearbox in
order to reduce the smell of burnt linings.
♦ Blow off dual mass flywheel with compressed air only.
♦ Clutch plate linings must make full contact with flywheel and
friction surface of clutch pressure plate. Only then insert se‐
curing bolts.
♦ Tighten securing bolts in small steps diagonally in order not to
damage centring holes of pressure plate and centring pins of
flywheel .
♦ 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.
2. Clutch 43
Polo 2014 ➤
Installation position of clutch plate

• Lettering “Getriebeseite” and protruding spring cage face
gearbox.
Check ends of diaphragm spring

• Wear to half the thickness of the diaphragm spring -arrows- is
permitted.
Checking spring connections and riveted connections

I - Extension springs OK.
• Minor kinks on the outside area -arrows A- have series pro‐
duction status.
II - Extension springs damaged
• Renew clutch pressure plates if springs are broken or badly
bent -arrow B-.

– Check spring connections between pressure plate and cover
for cracks and make sure rivet fastenings are seated tightly.
• A pressure plate with damaged spring connections or with
loose rivet connections -arrows- must be renewed.

Polo 2014 ➤
– Use counterhold tool - 3067- when installing.
For engines having a crankshaft of smaller diameter -arrow- or

having an needle bearing -arrow- in the crankshaft
Centring clutch plate and removing and installing pressure plate

for engines with a smaller crankshaft diameter, or with a needle
bearing in the crankshaft
Note
Disregard arrows -A- and -B-.
Continued for all
Mount pressure plate as follows so it is not deformed during in‐

stallation (leads to jolts when moving off):
– Make sure that stop pin (position setter) -arrow- can be moved
easily.
– Push pressure plate onto centring pins.
– Tighten all bolts evenly by hand until bolt heads contact pres‐
sure plate.
– Tighten all bolts in small steps and diagonally.
• Stop pin -arrow- must lift off pressure plate when this is done.
Specified torques
♦ Pressure plate to flywheel ⇒ page 38 .
2.2.2 Removing and installing clutch in conjunction with LuK dual-mass flywheel
2. Clutch 45
Polo 2014 ➤

equipment required

(ETKA) .
♦ For engines having a crankshaft of smaller diameter or having

needle bearings in the crankshaft - ⇒ page 45 centring man‐
drel - 3176-

Polo 2014 ➤
Removing
Gearbox is removed.
– Loosen bolts in small steps and diagonally.
Installing
Note

grease.
♦ Blow off dual mass flywheel with compressed air only.
curing bolts.
flywheel .
Installation position of clutch plate

• Lettering “Getriebeseite” (gearbox side) faces gearbox.
2. Clutch 47
Polo 2014 ➤

permitted.
Check extension springs and riveted connections

duction status.
• Renew clutch pressure plate if springs are broken or badly
bent -arrow B-.

– Make sure rivet joints -arrows B- on all extension springs
-arrows A- are firmly seated.
• Renew clutch pressure plate if riveting -arrows B- is loose.

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Checking position of adjusting mechanism with new pressure

plates only
• Both edges -A- of adjuster ring must be located between two
notches -arrows B-.
• If the adjuster ring takes up a different position in new pressure
plates, the pressure plate and clutch plate are not allowed to
be installed.
• The adjuster ring may take up a position outside the notches
in used clutches.
For engines having a crankshaft of smaller diameter -arrow- or

having an needle bearing -arrow- in the crankshaft
2. Clutch 49
Polo 2014 ➤
Centring clutch plate and removing and installing pressure plate

for engines with a smaller crankshaft diameter, or with a needle
bearing in the crankshaft
Note
Disregard arrows -A- and -B-.
Continued for all

Mount pressure plate as follows so it is not deformed during in‐
stallation (leads to jolts when moving off):
– Push pressure plate onto centring pins.
– Tighten all bolts evenly by hand until bolt heads contact clutch
pressure plate.
Specified torques
2.2.3 Removing and installing clutch in connection with simple flywheel

Polo 2014 ➤
equipment required

(ETKA) .
Removing
To prevent the pressure plate from becoming distorted during re‐
moval (causes clutch grab when driving off), always keep to the
following procedure when unbolting the pressure plate:
– Consecutively loosen all bolts in clockwise direction in 90°
stages until the clutch pressure plate is released.
Installing
Note

grease.
curing bolts.
flywheel .
2. Clutch 51
Polo 2014 ➤
• Installation position of clutch plate: lettering

“Getriebeseite” (gearbox end) or spring cage faces pressure
plate.

permitted.
Check spring connection and riveted fastenings.

– Check spring connection between thrust plate and cover for
cracks and make sure rivet fastenings are seated tightly.
– If pressure plate has damaged springs or loose rivet connec‐
tions -arrows-, it must be renewed.
Check extension springs and riveted connections

duction status.
• Renew clutch pressure plate if springs are broken or badly
bent -arrow B-.
– Check spring connections -arrows A- for damage, and make
sure that rivet joints -arrows B- are firmly seated.
• Renew clutch pressure plate if spring connections are broken
or badly bent, or if riveting is loose.

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– Make sure rivet joints -arrows B- on all extension springs

-arrows A- are firmly seated.
– Tighten all bolts one after another (clockwise) to final torque.
• Renew clutch pressure plate if riveting -arrow B- is loose.
Check metal ring.

– Check that metal ring in clutch pressure plate -arrow- is not
damaged.
• Renew clutch pressure plate if metal ring is broken.

Specified torques
2. Clutch 53
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34 – Controls, housing
1 Selector mechanism
⇒ “1.1 Installation position - selector mechanism”, page 54
⇒ “1.2 Assembly overview - gear knob and cover”, page 56
⇒ “1.3 Assembly overview - selector mechanism”, page 57
⇒ “1.4 Removing and installing gear knob”, page 59
⇒ “1.5 Removing and installing selector mechanism”, page 60
⇒ “1.6 Repairing selector mechanism”, page 63
⇒ “1.7 Adjusting selector mechanism”, page 65
⇒ “1.8 Checking selector mechanism”, page 67
⇒ “7.7 Renewing oil seal for selector shaft”, page 111
1.1 Installation position - selector mecha‐

nism
Note
♦ Disconnect battery before working on selector mechanism in

engine compartment ⇒ Electrical system; Rep. gr. 27 ; Bat‐
tery; Disconnecting and connecting battery .
♦ Removing and installing selector mechanism ⇒ page 60 .
Gear selection movement is indicated by -arrow A-

Gate selection movement is indicated by -arrow B-
54 Rep. gr.34 - Controls, housing

Polo 2014 ➤
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. Selector mechanism 55
Polo 2014 ➤
1.2 Assembly overview - gear knob and cover
1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
❑ Except for GT versions
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
⇒ page 59
3 - Clip
❑ For securing gear knob
to gear lever
❑ Secure to gear knob us‐
ing hose clip pliers -
V.A.G 1275 A-
4 - Centre console cover
❑ Combined with upper
part of centre console in
one part
❑ Is an individual part in
some equipment ver‐
sions ⇒ General body
repairs, interior; Rep.
gr. 68 ; Centre console;
Assembly overview –
centre console
5 - Noise insulation
❑ Not fitted in all vehicles
❑ Arrow on noise insulation points in direction of travel
❑ Locking lugs are arranged at varying intervals
❑ Therefore it can be installed in only one position

Polo 2014 ➤
1.3 Assembly overview - selector mechanism
Note
♦ Lubricate bearing positions and sliding surfaces.

♦ Allocate grease using ⇒ Electronic parts catalogue (ETKA) .
1 - Selector shaft with selector

shaft cover
2 - Seal
⇒ page 111
3 - Slide block
4 - Gate relay lever
❑ Grease before installing
⇒ page 64 .
⇒ page 64
❑ After installing, adjust
selector mechanism
⇒ page 65
5 - Securing clip
❑ For securing cable end-
piece to gate relay lever
6 - Cable end-piece
❑ For gate selector cable
to relay lever
selector mechanism
⇒ page 65
❑ Do not interchange; ca‐
ble end-pieces securing
gate selector cable to
gate relay lever and
gear selector cable to
gearbox selector lever
are different
❑ Allocation ⇒ page 63
❑ Installation position ⇒ page 64
❑ Install so that master spline aligns with selector shaft ⇒ page 64
❑ Grease before installing ⇒ page 64 .
❑ After installing, adjust selector mechanism ⇒ page 65
8 - Hexagon nut
❑ Self-locking
❑ 25 Nm
9 - Cable end-piece
❑ For gear selector cable to gearbox selector lever
Polo 2014 ➤
❑ Do not interchange; cable end-pieces securing gate selector cable to gate relay lever and gear selector
cable to gearbox selector lever are different
❑ Allocation ⇒ page 63
10 - Securing clip
11 - Gate change cable
❑ Connect to cable end-piece.
12 - Gear change cable
❑ Connect to cable end-piece.
13 - Hexagon nut
❑ Qty. 4
❑ M 6: 8 Nm
❑ M 8: 20 Nm
14 - Seal
❑ Between selector housing and underbody
❑ Renew selector housing after removing
❑ Self-adhesive
❑ Bond to selector lever housing
15 - Selector housing
16 - Securing clip
❑ Do not damage cables when removing
17 - Cable support bracket
18 - Hexagon bolt
❑ Qty. 2
❑ For cable support bracket
❑ 20 Nm
19 - Nut
❑ For cable support bracket
❑ 20 Nm
20 - Grommet
❑ Qty. 3
❑ Cable support bracket mounting on gearbox
21 - Spacer
❑ Qty. 3
22 - Bearing bush
23 - Securing clip
❑ Ensure proper engagement.

Polo 2014 ➤
1.4 Removing and installing gear knob

♦ Hose clip pliers - V.A.G 1275 A-
♦ Wedges - T10383-
♦ Or removal wedge - 3409- , depending on equipment version
Removing
– Using wedge - T10383- , carefully lever gear lever gaiter off
centre console insert -arrows-.
– Alternatively, use removal wedge - 3409- to lever out gear
lever gaiter.
Polo 2014 ➤
– Pull gear lever gaiter upwards off gear knob.

– Open clamp -arrow-, and pull off gear knob together with gear
lever gaiter.
Installing
– Press gear knob together with gear lever gaiter onto gear lever
as far as stop.
– Secure gear knob to gear lever with clamp -arrow-. Use hose
clip pliers - V.A.G 1275 A- to do this.
1.5 Removing and installing selector mech‐

anism
Removing
– Remove battery tray, battery and battery cover ⇒ Electrical
system; Rep. gr. 27 ; Battery; Removing and installing battery .
Continued for all
– Remove gear lever gaiter with gear knob and any noise insu‐
lation from frame for centre console ⇒ page 59 .
– Remove upper part of centre console together with securing
bracket for centre console and cup holder ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view – centre console .

Polo 2014 ➤
– Remove nuts for selector housing -arrows-.

– Lower selector housing.
– Remove damping from selector housing ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Centre console; Assembly over‐
view - centre console .
– Remove complete air filter housing if it is located over selector
mechanism ⇒ Rep. gr. 24 ; Air filter; Removing and installing
air filter .
– Detach securing clip -2- for gear selector cable from gearbox
selector lever -1-.
– Detach securing clip -4- for gate selector cable from relay lever
-3-.
– Pull gear selector cable and gate selector cable off pins
-arrows-.
– Remove cable support bracket -A- from gearbox -arrows-.
Caution
Risk of damage to decoupling element on exhaust pipe.

♦ Observe ⇒ Rep. gr. 26 ; Emission control; Assembly
overview - emission control .
– Remove heat shield below selector mechanism ⇒ General

body repairs, exterior; Rep. gr. 66 ; Mouldings/trims/exten‐
sions; Removing and installing floor heat shield .
– Swing selector lever housing down and remove with selector
cables.
Installing
– Align selector housing parallel to body.
• Distance to body must be same on both sides.
Bolt on selector housing.
Polo 2014 ➤
– Route Bowden cables -1- from selector mechanism -2- to

gearbox as follows:
• Bowden cables must lie parallel to each other and must not
cross.
• Bowden cables must be laid in the intended indentation in heat
shield -3-.
On some equipment versions, cables and heat shield are held in

position by clip -A-.
The holes in the cable end-pieces have different diameters.
Allocation of cable end-pieces ⇒ page 63
The cable end-pieces do not need to be renewed after being dis‐
mantled.
– Spread a small quantity of grease on pins -arrows- of gearbox
selector lever -1- and of relay lever -3-.

Polo 2014 ➤
Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

– Renew securing clips -2- and -4- after each removal.
– Secure gear selector cable with securing clip -2- and gate se‐
lector cable with securing clip -4-.
– Ensure proper engagement.
– Adjust selector mechanism ⇒ page 65 .
– Install centre console and cup holder ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Assembly overview –
centre console .
– Install gear lever gaiter with gear knob and, if present, noise
insulation ⇒ page 59 .
– Install heat shield below selector mechanism ⇒ General body
repairs, exterior; Rep. gr. 66 ; Mouldings/trims/extensions;
Removing and installing floor heat shield .
– Assemble exhaust system free of tension ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers; Assembly overview - silencer .
– If removed, install complete air filter housing ⇒ Rep. gr. 24 ;
Air filter; Removing and installing air filter housing .
– If removed, install battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
Specified torques
♦ Selector housing to body ⇒ page 57
♦ Selector cable support bracket to gearbox ⇒ page 57
1.6 Repairing selector mechanism

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 gearbox selector lever 8.5 mm
-2- Gate selector cable to gate relay lever 10 mm
Polo 2014 ➤
Installation position of gearbox selector lever/gate relay lever

2 - Gate relay lever engages in guide rail of gearbox selector lever
via shoe -arrow-.
Gate relay lever: thoroughly grease following areas in particular

prior to installation
• Shaft -A- of gate relay lever -arrows-.
• For grease allocation, refer to ⇒ Electronic parts catalogue
(ETKA) .
The illustration shows a plastic gate relay lever.
Gearbox selector lever: thoroughly grease following areas in par‐

ticular prior to installation
• Guide rail -B- of gearbox selector lever into which gate relay
lever engages.
• Support pin for cable end-piece.
• For grease allocation, refer to ⇒ Electronic parts catalogue
(ETKA) .
• Illustration of gate relay lever and gearbox selector lever may
differ from actual components.
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 2014 ➤
Installation position of securing clips -1- and -2-.
1.7 Adjusting selector mechanism

♦ Locking pin - T10027 A-
Prerequisites for adjustment

• Moving parts of selector mechanism and elements transferring
force must be in proper condition.
• Selector mechanism must move freely.
• Gearbox, clutch and clutch mechanism must be in proper con‐
dition.
• Gearbox must be in neutral.
– Remove complete air filter housing if angled rod -A- for secur‐
ing selector shaft and locking mechanism for gear selector
cable and gate selector cable are not accessible ⇒ Rep. gr.
24 ; Air filter; Removing and installing air filter housing .
Polo 2014 ➤
– 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-.
• It must be possible to push the cables into the cable end-piece.
• Gearbox must be in neutral.
Secure selector shaft as follows:

– Press selector shaft down in -direction of arrow 1-.
– While pressing down selector shaft, turn angled rod -A- in
-direction of arrow 3- upwards and at the same time press it in
-direction of arrow 2- until it engages in selector shaft.
– Pull gaiter with gear knob upwards, inside out over gear knob.
– Remove noise insulation, if present ⇒ page 59 .
– Move gear lever to neutral position, press it to left and hold in
this position.
– Push locking pin - T10027 A- through hole -A- into hole -B-.
– Wrap left seat belt -1- around gear lever so that the belt holds
the lever.
The gear lever is secured in place 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«.

Polo 2014 ➤
– Now turn locking mechanisms on gear selector cable and gate

selector cable end pieces clockwise to stop
-direction of arrow 1-.
The spring presses the locking mechanism into original position
– Then turn angled rod -A- back to original position in

• During this procedure, locking pin -A- must be pressed out of
gearbox in -direction of arrow 1-.
– Remove seat belt from selector lever.

– Pull locking pin out of holes -A- and -B-.
– If noise insulation was present, install it.
– Carefully install gaiter with frame ⇒ page 59 .
– Check selector shaft can move freely.
To do this, move selector shaft »back and forth« on gearbox at
front by hand.
– Check selector mechanism
⇒ “1.8 Checking selector mechanism”, page 67 .
1.8 Checking selector mechanism

• With gearbox in neutral, gear lever must be in gear lever 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 65 .
Polo 2014 ➤
2 Removing and installing gearbox

⇒ “2.1 Removing gearbox”, page 68
⇒ “2.2 Installing gearbox”, page 89
2.1 Removing gearbox

⇒ “2.1.1 Removing gearbox, vehicles with 1.4 l engine”,
page 68
⇒ “2.1.2 Removing gearbox, vehicles with 1.8 l engine”,
page 77
2.1.1 Removing gearbox, vehicles with 1.4 l engine

equipment required
♦ Support bracket - 10 - 222 A-

♦ Adapter - 10 - 222 A /8-
♦ Shackle - 10 - 222 A /12-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/33-

Polo 2014 ➤
♦ Support elements for gearbox (determine when setting ad‐

justment plate on gearbox support )
♦ Gearbox lifting tackle - 3336- for transporting gearbox

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Or engine and gearbox jack - VAS 6931-
(ETKA) .
2. Removing and installing gearbox 69

Polo 2014 ➤
♦ Hose clamp - 3094-
♦ Tensioning strap - T10038-
♦ Adapter - VW 771/40- from multi-purpose tool - VW 771-

(ETKA) .
♦ Hexagon head bolt M10 x 20
At a later point, support bracket - 10-222 A- will be fitted onto
longitudinal members with adapters - 10 - 222 A /8- .

Polo 2014 ➤
• To prevent damage to edges of wings, cover bottom area of

both adapters - 10 - 222 A /8- with self-adhesive fabric tape
-arrow- ⇒ Electronic parts catalogue (ETKA chemical sub‐
stances) .
– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
Battery in luggage compartment
– Detach fuse holder A - SA- above left assembly mounting ⇒
Electrical system; Rep. gr. 97 ; Relay carriers, fuse holders,
electronics boxes; Overview of fitting locations - relay carriers,
fuse holders, electronics boxes .
Continued for all

– Detach securing clip -1-, and pull gear selector cable -2- off
gearbox selector lever.
– Detach securing clip -4-, and pull gate selector cable -3- off
gate relay lever.
– Remove cable support bracket -A- from gearbox -arrows-,

raise and secure.

Polo 2014 ➤
– Pull securing clip -arrow A- off relay lever -1- and remove relay
lever.
– Remove gearbox selector lever -2- by removing nut
-arrow B-.
– If fitted, remove earth strap -3- from top starter bolt.
– Pull connector -4- off reversing light switch - F4- .
– Remove connector -5- and wire from starter.
– Unscrew upper engine/gearbox connecting bolts -arrows-.

The bolt heads might differ from those shown in the diagram.
– Then remove upper securing bolt on starter.
– If the upper securing bolt for the starter cannot be pulled out,
remove bleeder connection ⇒ page 31 .
Vehicles with pipeline between clutch master and slave cylinder

– Clamp off supply hose from brake fluid reservoir to clutch
master cylinder with hose clamp - 3094- .

Polo 2014 ➤
Vehicles with pipe/hose line between clutch master and slave

cylinder
– Clamp off hose of pipe/hose line -A- from clutch master cylin‐
der to clutch slave cylinder using hose clamp - 3094- .
Continued for all
– Pull out clip -arrow- for pipe/hose line or pipeline to stop.
– Pull pipe/hose line or pipe out of clutch slave cylinder bleeder
and seal.
– Tie up line.
Caution
Risk of contamination due to brake fluid spill.

♦ Do not operate clutch pedal after detaching pipe/hose line
from bleeder connection on clutch slave cylinder.
– Remove foam pieces or seal from upper edge of left and right
wings ⇒ General body repairs, exterior; Rep. gr. 50 ; Wings;
Assembly overview – wings .
– If there are hose and cable connections in area of engine sup‐

port eyes for support bracket - 10-222 A- , remove these now.
– Set up support bracket - 10-222 A- behind bonnet support.
– Items to be used:
♦ Adapter - 10 - 222 A /8-
♦ Shackle - 10 - 222 A /12-
♦ Tensioning strap - T10038-
• Position both adapters - 10 - 222 A /8- right in front of the

shoulder -arrow-.
• Pay attention to paint on edges -arrow-.
– Secure both adapters - 10 - 222 A /8- with tensioning straps -
T10038- .
• Tensioning straps must be guided past bonnet hinge/body as
close as possible to bolted connection.
– Attach support bracket - 10-222 A- to engine support eyes.

Polo 2014 ➤
Use shackle - 10 - 222 A /12- -1- to hook in the spindles.

– Take up weight of engine/gearbox assembly.
The left drive shaft will be removed in a later step.

– With vehicle standing on its wheels, loosen front left flange bolt
-arrow- 90° at most, or wheel bearing will be damaged ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Re‐
moving and installing drive shaft .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Assembly overview
- front wheel housing liner .
– Remove all lines from gearbox.

– If fitted, disconnect connectors as follows
– Gearbox with gearbox neutral position sender - G701- : Pull
off connector -arrow-.
– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter .

Polo 2014 ➤
– Remove coupling rod -1- from anti-roll bar on both sides ⇒

Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview – subframe .
– Press anti-roll bar upwards.
– If fitted, detach drive shaft heat shield -arrows- ⇒ Running

gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft heat shield .
– Remove right drive shaft from flange shaft, raise as high as
possible and secure. Do not damage surface protection ⇒
Remove left drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shafts .
– Remove pendulum support -A- from gearbox -arrows-.

– Fix subframe -B- in position prior to removal ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Fixing subframe in
position .
– Remove subframe -B- with pendulum support -A- ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Subframe; Assembly over‐
view - subframe .
– Remove bolts -arrows- on left assembly mounting -2- from

bracket -1-.
– Tilt engine/gearbox assembly. To do this, lower it via spindles
of gearbox support - 10 - 222 A- .

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– Remove bracket -1- from gearbox -arrows A, B- and

-arrow C-.
Gearbox support - 3282- is aligned with adjustment plate -

3282/33- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack .
– Align arms of gearbox support according to holes in adjust‐
ment plate .
– Attach support elements -A- to adjustment plate as illustrated.
– Screw in pin - 3282/29- instead of support element -C-.
– Position engine and gearbox jack under vehicle. Arrow -B- on
adjustment plate points in direction of vehicle travel.
– Align adjustment plate parallel to gearbox.
– Secure adapter - VW 771/40- in threaded hole of gearbox

housing as shown in figure.
– Then screw pin - 3282/29- into rear hole on gearbox for se‐
curing bolt of pendulum support.
– Secure gearbox to gearbox support - 3282- using bolt (M10 ×
20) -A-.
– Remove engine/gearbox connecting bolt -arrow-.

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– Remove engine/gearbox connecting bolt -A- above right

flange shaft.
The bolt head might differ from the one shown in the diagram.
– Remove lower engine/gearbox connecting bolts.
– Press gearbox away from engine, off dowel sleeves.
– Tilt gearbox to left using spindles of gearbox support - 3282- .
– Carefully lower gearbox, guiding gearbox past flywheel.
– Bear in mind longitudinal member in the process -arrows-.

– Lower gearbox carefully.
Note
♦ Be careful of all lines when lowering gearbox.

♦ Observe lower coolant hose between radiator and engine.
2.1.2 Removing gearbox, vehicles with 1.8 l engine

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equipment required
♦ Rack - 10 - 222 A /1-

♦ Spindle - 10 - 222 A 10-
♦ Adapter - 10 - 222 A /18-
♦ Adapter - 10 - 222 A /20-
♦ Adapter - 10 - 222 A /28-
♦ Adapter - 10-222 A /28-2-
♦ Spindle - 10 - 222 A /32-

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♦ Square tube and 2 wing bolts from support bracket - 10 - 222

A-
♦ Not required here: adapter - 10 - 222 A /8-
♦ Gearbox support - 3282-
♦ Adjustment plate - 3282/33-
♦ Support elements for gearbox (determine when setting ad‐
justment plate on gearbox support )
♦ Gearbox lifting tackle - 3336- for transporting gearbox

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♦ Square section tube - T40091/1- (qty. 1)
Rotary joint - T40091/3- (qty. 1)

♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Or engine and gearbox jack - VAS 6931-

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♦ Hose clamp - 3094-
♦ Adapter - VW 771/40- from multi-purpose tool - VW 771-
♦ Spindle from assembly tool - 3066-
♦ Thrust piece - 3124-

(ETKA) .

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♦ Hexagon head bolt M10 x 20

– Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover
panel; Removing and installing engine cover panel .
– Pull off left and right mounting for engine cover panel ⇒ Rep.
gr. 10 ; Assembly mountings; Supporting engine in installation
position .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray .
Continued for all
– Detach securing clip -1-, and pull gear selector cable -2- off
gearbox selector lever.
– Detach securing clip -4-, and pull gate selector cable -3- off
gate relay lever.
– Remove cable support bracket -A- from gearbox -arrows-,

raise and secure.
– Pull securing clip -arrow A- off relay lever -1- and remove relay
lever.
– Remove gearbox selector lever -2- by removing nut
-arrow B-.
– If fitted, remove earth strap -3- from top starter bolt.
– Pull connector -4- off reversing light switch - F4- .
– Remove connector -5- and wire from starter.

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– Unscrew upper engine/gearbox connecting bolts -arrows-.

The bolt heads might differ from those shown in the diagram.
– Then remove upper securing bolt on starter.
– If the upper securing bolt for the starter cannot be pulled out,
remove bleeder connection ⇒ page 31 .
Vehicles with pipeline between clutch master and slave cylinder

– Clamp off supply hose from brake fluid reservoir to clutch
master cylinder with hose clamp - 3094- .
Vehicles with pipe/hose line between clutch master and slave

cylinder
– Clamp off hose of pipe/hose line -A- from clutch master cylin‐
der to clutch slave cylinder using hose clamp - 3094- .
Continued for all
– Pull out clip -arrow- for pipe/hose line or pipeline to stop.
– Pull pipe/hose line or pipe out of clutch slave cylinder bleeder
and seal.
– Tie up line.
Caution
Risk of contamination due to brake fluid spill.

♦ Do not operate clutch pedal after detaching pipe/hose line
from bleeder connection on clutch slave cylinder.
– Remove foam pieces or seal from upper edge of left and right
wings ⇒ General body repairs, exterior; Rep. gr. 50 ; Wings;
Assembly overview – wings .
– If there are hose and cable connections in area of engine sup‐
port eyes for support bracket - 10-222 A- , remove these now.

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– Prepare support bracket as shown in illustration, and fit it onto

edges of wings.
– Unscrew bolt -1- on left of lock carrier.
– Unscrew lower mounting from adapter - 10 - 222 A /28- , and

replace it with adapter - 10-222 A /28-2- .
– Unscrew one securing bolt -arrow- from adapter -10-222 A /
28-2- .

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– Bolt adapter - 10-222 A /28-2- to lock carrier using securing

bolt -1-.
– Slide square section tube - T40091/1- through adapter - 10 -

222 A /28- and rotary joint - T40091/3- .
– Tighten all threaded connections of support bracket hand-
tight.
– Attach spindle - 10 - 222 A /32- with adapter - 10 - 222 A /20-
on right lifting eye.
– Attach spindle - 10 - 222 A 10- on left lifting eye.
– Take up weight of engine/gearbox assembly using spindles .
The left drive shaft will be removed in a later step.

– With vehicle standing on its wheels, loosen front left flange bolt
-arrow- 90° at most, or wheel bearing will be damaged ⇒
sulation .
– Remove front left wheel housing liner ⇒ General body repairs,
- front wheel housing liner .
– Remove all lines from gearbox.

– If fitted, disconnect connectors as follows
– Gearbox with gearbox neutral position sender - G701- : Pull
off connector -arrow-.

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– Pull connector -1- off oil level and oil temperature sender -
G266- .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter .
– Remove coupling rod -1- from anti-roll bar on both sides ⇒

Running gear, axles, steering; Rep. gr. 40 ; Subframe; As‐
sembly overview – subframe .
– Press anti-roll bar upwards.
– Remove right drive shaft from flange shaft, raise as high as
possible and secure. Do not damage surface protection ⇒
• The right flange shaft must be removed, so that the lower en‐
gine/gearbox connecting bolt can be unscrewed.
– Unscrew bolt -arrow- for right flange shaft. Screw 2 bolts into
flange and counter hold flange shaft using a lever.
– Pull out flange shaft with compression spring.
Note
♦ Before removing flange shaft, check oil seal for leaks. If oil seal
leaks, it must be renewed during installation ⇒ page 188 .
♦ If gear oil escapes during removal of the flange shaft, top gear
oil up again with gearbox and flange shaft installed
⇒ page 99 .
– Screw spindle -A- of assembly tool - 3066- into threaded piece

of differential.
– Attach thrust piece - 3124- with nut -B-.
Note
The thrust piece - 3124- is intended to protect the right oil seal
and the gearbox against dirt.
Remove left drive shaft ⇒ Running gear, axles, steering; Rep. gr.

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– Remove pendulum support -A- from gearbox -arrows-.

– Fix subframe -B- in position prior to removal ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Fixing subframe in
position .
– Remove subframe -B- with pendulum support -A- ⇒ Running
view - subframe .
– Detach bracket for air filter housing, and push it aside slightly
⇒ Rep. gr. 10 ; Assembly mountings; Removing and installing
gearbox mounting .
Continued for all

– Remove bolts -arrows- on left assembly mounting -2- from
bracket -1-.
– Tilt engine/gearbox assembly. To do this, lower it via spindles
of gearbox support - 10 - 222 A- .
– Remove bracket -1- from gearbox -arrows A, B- and

-arrow C-.

3282/33- for removal of gearbox.
– Insert gearbox support - 3282- in engine and gearbox jack .
ment plate .
– Position engine and gearbox jack under vehicle. Arrow -B- on
– Align adjustment plate parallel to gearbox.

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– Secure gearbox to gearbox support - 3282- using bolt (M10 x
20) -A-.
– Remove engine/gearbox connecting bolt -arrow-.

– Remove lower engine/gearbox connecting bolts.
– Press gearbox away from engine, off dowel sleeves.
– Carefully lower gearbox, guiding gearbox past flywheel.
– Bear in mind longitudinal member in the process -arrows-.

– Lower gearbox carefully.
Note
♦ Be careful of all lines when lowering gearbox.

♦ Observe lower coolant hose between radiator and engine.
– If necessary, install right flange shaft again (shown here with

a different gearbox).
– Tighten countersunk bolt -arrow- to specified torque
⇒ page 195 .

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2.2 Installing gearbox
Note
♦ Refer to procedure “Removing gearbox” for the required spe‐

cial tools.
♦ Vehicles with 1.4 l engine ⇒ page 68 .
♦ Vehicles with 1.8 l engine ⇒ page 77 .
♦ All cable ties which were opened or cut open during removal
must be replaced with new ties in same position during instal‐
lation.
Manual gearbox without oil filler plug ⇒ page 99

Observe the following table on the subject of “checking and top‐
ping up gear oil”.
“Checking and topping up gear oil”
»no« »yes« »yes«
Gearbox New gear‐ X
box (genu‐
ine part)
No oil loss X
Oil loss X
After instal‐
lation
⇒
page 100
Completely X
dismantled before in‐
stallation
⇒ Item 12
(page 107)
and
⇒ Item 5
(page 131)
oil capacity
⇒ page 3
Partially X
dismantled After instal‐
• (Gear‐ lation
box ⇒
housing page 100
and
clutch
housing
were not
separa‐
ted)
Continued for all

– All threaded holes into which self-locking bolts are to be
screwed must be cleaned of residual locking fluid carefully with
a thread chaser.
– Renew self-locking bolts and nuts after each removal.
– Check whether dowel sleeves for aligning engine and gearbox

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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.
– Check that intermediate plate is hooked into sealing flange
and pushed onto dowel sleeves -arrows-.
– Clean input shaft splines and apply thin coat of grease for
clutch plate splines .
The clutch plate must slide easily to and fro on the input shaft.
– Check clutch release bearing for wear. Renew clutch slave
cylinder with release bearing if necessary ⇒ page 34 .

3282/33- for installation of gearbox.
ment plate .
– Place gearbox on engine and gearbox jack .
– Align adjustment plate and gearbox parallel to one another.

– Secure gearbox to gearbox support - 3282- using bolt (M10 x
20) -A-.
– Position engine and gearbox jack under vehicle. -Arrow B- on
Vehicles with 1.8 l engine

– If not already removed, remove right flange shaft -arrow-
(shown here with a different gearbox).
Note
♦ Before removing flange shaft, check oil seal for leaks. If oil seal
leaks, it must be renewed during installation ⇒ page 188 .
♦ If gear oil escapes during removal of the flange shaft, top gear
oil up again with gearbox and flange shaft installed
⇒ page 99 .

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– Screw spindle -A- of assembly tool - 3066- into threaded piece

of differential.
– Attach thrust piece - 3124- with nut -B-.
Note
The thrust piece - 3124- is intended to protect the right oil seal
and the gearbox against dirt.
Continued for all

– Raise gearbox, guiding gearbox past longitudinal member
-arrows- and flywheel.
Note
Observe lower coolant hose between radiator and engine and all
other lines.
– Align gearbox to engine and join.

– Screw in engine/gearbox connecting bolt -arrow- and tighten
it ⇒ page 96 .

– Screw in and tighten engine/gearbox connecting bolt -A-
above right flange shaft ⇒ page 96 .
The bolt head might differ from the one shown in the diagram.

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– Re-insert right flange shaft, and tighten countersunk bolt
-arrow- to specified torque ⇒ page 195 .
Continued for all
– Screw in lower engine/gearbox securing bolts and tighten
them ⇒ page 96 .
– After gearbox has been bolted to engine, remove engine and
gearbox jack from gearbox.
– Screw in upper engine/gearbox securing bolts and tighten
them ⇒ page 96 .
– Install bracket -1- on gearbox using new hexagon bolts

-arrows A, B- and -C- and tighten to specified torque
⇒ page 97 .
To prevent damage to the thread in the gearbox support, gearbox
mounting and gearbox support must be parallel to each other.
– Align engine and gearbox in installation position. Do this by

tightening threaded spindle until bracket -1- fully rests against
assembly mounting -2-.
– Screw new bolts -arrows- for left assembly mounting -2- into
bracket -1- and tighten them ⇒ page 97 .
– Do not remove engine support bracket - 10 - 222 A- until all
bolts securing the assembly mounting have been tightened to
specified torque.
Note
Install engine and gearbox mounting free of tension ⇒ Rep. gr.

10 ; Removing and installing engine .

– Remove adapter - 10 - 222 A /28- , and install lock carrier to
left retaining bracket (bolt -1-) ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Lock carrier; Removing and installing lock
carrier .

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Continued for all

– Install subframe -B- ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Assembly overview - subframe .
– Install pendulum support -A- to gearbox using new bolts
-arrows- ⇒ Rep. gr. 10 ; Assembly mountings; Assembly
overview - assembly mountings .
– Install coupling rod -1- to anti-roll bar on both sides ⇒ Running

view – subframe .
– If fitted, connect connectors as follows:

– Gearbox with gearbox neutral position sender - G701- : Push
on connector -arrow-.
– Fit connector -1- to oil level and oil temperature sender -

G266- .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
– If fitted, install drive shaft heat shield ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft heat shield .
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter .

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– Install upper starter bolt, and attach connector -5- and wiring
to starter ⇒ Electrical system; Rep. gr. 27 ; Starter .
– If necessary, install bleeder connection ⇒ page 31 .
– Push connector -4- onto reversing light switch - F4- .
– Attach earth strap -3- to upper starter bolt.
– If fitted, connect earth strap at top.
– Install gearbox selector lever -2- ⇒ page 64 .
– Tighten hexagon nut -arrow B- ⇒ page 108 .
– Insert relay lever -1- and clip in securing clip -arrow A-.
– Push pipe/hose line or pipe -A- into bleeder of clutch slave

cylinder up to stop. Push down clip -arrow-.
– Remove hose clamp - 3094- from pipe/hose line or supply
hose.
– After removing hose clamp - 3094- , return supply hose to its
original shape, if necessary.

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– Install cable support bracket -A- on gearbox and tighten bolts

and nut -arrows- ⇒ page 57 .
– Connect gear selector cable to gearbox selector lever and
gate selector cable to gate relay lever ⇒ page 60 .
– Check for correct installation position of vacuum hose for
brake system. Fit vacuum hose, if necessary ⇒ Brake system;
Rep. gr. 47 ; Brake servo/brake master cylinder .
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing battery tray .
– Install fuse holder A - SA- above left assembly mounting ⇒
Electrical system; Rep. gr. 97 ; Relay carriers, fuse holders,
electronics boxes; Overview of fitting locations - relay carriers,
fuse holders, electronics boxes .
Or
– Install bracket for air filter housing ⇒ Rep. gr. 10 ; Assembly
mountings; Removing and installing gearbox mounting .
Continued for all
Removing and installing battery .
– Install foam pieces or seal at upper edge of left and right wings
⇒ General body repairs, exterior; Rep. gr. 50 ; Wings; As‐
sembly overview – wings .
– Install engine cover panel ⇒ Rep. gr. 10 ; Engine cover panel;
Removing and installing engine cover panel .
Manual gearbox “with” oil filler plug
– Check oil level in gearbox ⇒ page 99 .
Manual gearbox “without” oil filler plug
– Observe table. ⇒ page 89
Continued for all
– Install front left wheel housing liner ⇒ General body repairs,
– front wheel housing liner .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview - noise insula‐
tion .

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2.3 Specified torques for gearbox

⇒ “2.3.1 Specified torques for gearbox, vehicles with 1.4 l engine”,
page 96
⇒ “2.3.2 Specified torques for gearbox, vehicles with 1.8 l engine”,
page 96
2.3.1 Specified torques for gearbox, vehicles

with 1.4 l engine
Item Bolt Quantity Nm
1 M12 x 60 1 80
♦ With long M8 stud
2 M12 x 60 1 80
3 M12 x 170 2 80
♦ With M8 stud
♦ Additionally, starter to gearbox
4 M10 x 110 1 40
5 M10 x 50 2 40
6 M12 x 65 2 80
Item -A- dowel sleeves for centring
2.3.2 Specified torques for gearbox, vehicles

with 1.8 l engine
Item Bolt Quantity Nm
1 M 12 x 55 1 80
♦ With long M8 stud
2 M12 x 50 1 80
3 M12 x 170 2 80
♦ With M8 stud
♦ Additionally, starter to gearbox
4 M 10 x 105 1 40
5 M 10 x 50 2 40
6 M 12 x 65 1 80
Item -A- dowel sleeves for centring

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3 Assembly mountings
⇒ “3.1 Assembly overview - assembly mountings”, page 97
3.1 Assembly overview - assembly mount‐

ings
Gearbox bracket -1- to gearbox.
– Renew bolts.
When installing gearbox bracket, observe the following se‐
quence:
– Tighten all bolts -arrows A, B- and -C- hand-tight.
– Tighten bolt -A- to 40 Nm + 90°.
– Tighten bolts -B- and -C- to 40 Nm + 90°.
Gearbox bracket -1- to left assembly mountings -2-

– Renew bolts.
Bolts -arrows-: 40 Nm + turn 90° further.
Gearbox with threaded insert (e.g. “Heli coil”) for securing pen‐
dulum support
Note
♦ There are threaded inserts, e.g. “Heli coil” in the bolting holes
for the pendulum support.
♦ Distinguishing feature: shoulder along beginning of thread
-arrow-.
♦ Make sure to use appropriate securing bolts and observe
specified torque ⇒ Rep. gr. 10 ; Assembly mountings; As‐
sembly overview - assembly mountings .
♦ Adjust assembly mountings ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Assembly overview - assembly mountings
3. Assembly mountings 97
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4 Transporting gearbox
♦ Gearbox mounting support - 3336-
– Bolt gearbox lifting tackle - 3336- to clutch housing.
– Adjust support beam on sliding piece using locking pin

-arrow-.
Number of holes visible = 6.
– Lift gearbox using workshop crane and gearbox lifting tackle -
3336- .
– Set gearbox aside, for example in a transport container.

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5 Gear oil
⇒ “5.1 Distinguishing between different manual gearbox types
when filling oil”, page 99
⇒ “5.2 Checking gear oil level”, page 99
⇒ “5.2.4 Specified torque for oil filler and oil drain plugs”,
page 102
5.1 Distinguishing between different manual

gearbox types when filling oil
A number of manual gearboxes is not fitted with an oil filler plug
-arrow-.
• Please also note the following table:
Manual gearbox
“With” oil filler plug “Without” oil filler plug
Check gear oil level Check gear oil level
⇒ page 99 . ⇒ page 100 .
5.2 Checking gear oil level

⇒ “5.2.1 Checking gear oil level, gearboxes with oil filler plug”,
page 99
⇒ “5.2.2 Checking gear oil level, gearboxes without oil filler plug”,
page 100
5.2.1 Checking gear oil level, gearboxes

“with” oil filler plug
♦ Socket bit - 3357- for oil filler plug with multi-point socket head
bolt
5. Gear oil 99
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Gear oil ⇒ Electronic parts catalogue (ETKA)

sulation .
– To check gear oil, remove oil plug -arrow-.
Oil level is correct when gearbox is filled to lower edge of filler
hole.
– If necessary, fill with gear oil to lower edge of filler hole.
– Screw in plug -arrow- with new seal, if fitted.
– Tighten bolt -arrow- ⇒ page 102 .
tion .
5.2.2 Checking gear oil level, gearboxes

“without” oil filler plug
Proceed as follows when checking gear oil level on manual gear‐
boxes “without” oil filler plug -arrow-:
The oil level in the gearbox can only be checked by completely
draining the gear oil and then refilling it ⇒ page 100 .
5.2.3 Draining an adding gear oil, manual

gearbox “without” oil filler plug

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♦ Hose (approx. 600 mm long, outer diameter 18 mm ) with fun‐

nel, commercially available.
Drain gear oil.
Gear oil ⇒ Electronic parts catalogue (ETKA) .
– Remove complete air filter housing if it is located above locking
bolt for selector shaft.
Vehicles with turbo diesel engine
– ⇒ Rep. gr. 23 ; Air filter; Removing and installing air filter
housing
Vehicles with petrol engine
housing
Continued for all
sulation .
Clean gearbox.
Use a clean container (capacity 3.0 l) with a graduated scale to
collect gear oil.
– Unscrew oil drain plug -arrow- to drain gear oil.
– Screw in oil drain plug ⇒ page 102 .
Fill with gear oil
• The oil drain plug is tightened to specified torque.
Gear oil ⇒ Electronic parts catalogue (ETKA)
Top up gear oil in receptacle to 2.15 l.
• Selector shaft is in neutral position (shown here on a different

gearbox).
5. Gear oil 101

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– Unscrew locking bolt -arrow-.

– Fit a hose (approx. 600 mm long, external diameter 18 mm)
onto a funnel (commercially available).
– Insert hose into mounting hole of locking bolt (second me‐
chanic), and fill in gear oil.
– Install new locking bolt ⇒ Item 12 (page 107) .
– If removed beforehand, install complete air filter housing.
Vehicles with turbo diesel engine
housing
Vehicles with petrol engine
housing
Continued for all
tion .
5.2.4 Specified torque for oil filler and oil drain

plugs
Various versions of oil filler and drain plug
I - Oil filler or oil drain plug with multi-point socket head: 45 Nm
II - Oil filler or oil drain plug with hexagon socket head: 35 Nm

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6 Installing to engine and gearbox sup‐

port
♦ Support clamp - VW 313-
♦ Support plate - VW 309-

♦ or support plate - VW 309 A-
♦ Gearbox support - VW 353-
– Secure gearbox on gearbox support - VW 353- -arrows-.

– Place drip tray underneath.
Note
If one of the bolting holes does not contact the gearbox support ,
fit washers between hole and gearbox support .
6. Installing to engine and gearbox support 103

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7 Dismantling and assembling gearbox

⇒ “7.1 Schematic overview - gearbox”, page 104
⇒ “7.2 Assembly overview - gearbox”, page 105
⇒ “7.3 Assembly overview - gearbox housing and selector mech‐
anism”, page 106
⇒ “7.4 Assembly overview - selector unit”, page 108
⇒ “7.5 Assembly overview - shafts, differential, selector mecha‐
nism”, page 109
⇒ “7.6 Assembly overview - selector forks”, page 111
⇒ “7.7 Renewing oil seal for selector shaft”, page 111
⇒ “7.8 Removing and installing selector unit with gearbox instal‐
led”, page 113
⇒ “7.9 Dismantling and assembling gearbox”, page 116
7.1 Schematic overview - gearbox
1 - Clutch housing
2 - Reverse shaft
reverse gears
4 - Clutch slave cylinder with
release bearing
5 - Input shaft
gear
7 - Differential
8 - Right flange shaft
9 - Left flange shaft
10 - Synchromeshed gear for
2nd gear
1st gear
4th gear
3rd gear
5th gear
6th gear
reverse gear
17 - Gearbox housing

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7.2 Assembly overview - gearbox
l-
gearbox housing and selector
mechanism”, page 106
l-
⇒ “7.4 Assembly overview - se‐
lector unit”, page 108
lI -
shafts, differential, selector
ll -
⇒ “7.6 Assembly overview - se‐
lector forks”, page 111
7. Dismantling and assembling gearbox 105

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7.3 Assembly overview - gearbox housing and selector mechanism
1 - Countersunk bolt
❑ Specified torque
⇒ page 195
❑ With compression
spring and tapered ring.
⇒ page 189
❑ Assembling
⇒ page 195
3 - Retaining ring
❑ For sheet metal cover
plate
❑ Discontinued for plastic
cover plate
4 - Sealing cap
❑ Made of sheet metal or
plastic ⇒ page 122
❑ If made of sheet metal -
secured with retaining
ring.
❑ If made of plastic - with‐
out retaining ring.
❑ Allocate components
using ⇒ Electronic parts
catalogue (ETKA)
5 - Retaining ring
❑ For deep groove ball
bearing of input shaft
⇒ page 144
6 - Reversing light switch - F4-
❑ Switch without seal:
clean thread of switch if
necessary
❑ Switch without seal: install switch with sealant if necessary
❑ For allocation of sealant, refer to ⇒ Electronic parts catalogue (ETKA) .
❑ Switch with encapsulated seal: renew switch
❑ Switch with separate seal: renew seal
❑ Lightly coat lug with MoS2 grease
❑ 20 Nm
7 - Seal
❑ Not fitted in all gearboxes
❑ If fitted, renew after removal
8 - Oil drain plug
❑ Specified torque ⇒ page 102
9 - Seal
10 - Bolt
❑ 6 Nm

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11 - Gearbox neutral position sender - G701-

❑ For vehicles with start/stop system
❑ Allocate components using ⇒ Electronic parts catalogue (ETKA)
12 - Locking bolt
❑ For selector shaft
❑ Renew locking bolt after each removal.
❑ Locking bolt made of metal or plastic.
❑ Locking bolt made of metal: 45 Nm
❑ Locking bolt made of plastic: 30 Nm
❑ On gearboxes without oil filler plug, fill oil through threaded hole for locking bolt ⇒ “5 Gear oil”, page 99
13 - Bolt
❑ Aluminium bolt M9
❑ 15 Nm and turn 180° further
14 - Bolt
❑ Aluminium bolt M9
❑ 15 Nm and turn 180° further
15 - Selector unit
❑ (Selector shaft with selector shaft cover) ⇒ page 108
❑ Removing and installing with gearbox installed:
♦ Remove complete air filter housing in vehicles with petrol engine ⇒ Rep. gr. 24 ; Air filter; Removing and
installing air filter housing .
♦ Remove battery and battery tray, if necessary ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
installing battery .
♦ The angled rod ⇒ Item 6 (page 131) for adjusting the selector mechanism must not be engaged.
♦ Remove selector cables and gearbox selector lever ⇒ page 57
♦ Unscrew locking bolt.
♦ If fitted, remove gearbox neutral position sender - G701- .
♦ Unscrew bolts and pull out selector unit.
♦ Install in reverse order of removal. Renew O-ring and bolts.
16 - Bolt
❑ 20 Nm
17 - O-ring
18 - Clutch housing
❑ Repairing ⇒ page 131

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7.4 Assembly overview - selector unit
1 - Hexagon nut
❑ Self-locking
❑ 23 Nm
❑ Can be renewed with
the selector mechanism
installed
⇒ page 64
❑ Installing ⇒ page 64
selector mechanism
⇒ page 65
3 - Seal for selector shaft
⇒ page 111
4 - Bearing bush
❑ For relay lever
5 - Securing clip
❑ For relay lever
6 - Selector unit
❑ Consists of selector
shaft and selector shaft
cover
❑ Components cannot be
separated from each
other
❑ Can be removed and in‐
stalled with gearbox in‐
stalled ⇒ page 106 .
7 - Bearing bush
8 - O-ring
❑ Insert in peripheral groove of selector mechanism cover
❑ Coat with gear oil when installing
9 - Cap
❑ For gearbox breather
10 - Deflector lever
❑ After installing, adjust selector mechanism, ⇒ page 65

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7.5 Assembly overview - shafts, differential, selector mechanism

gear
❑ Dismantling and assem‐
bling ⇒ page 151
⇒ page 110
2 - Selector rod with selector
fork for 1st and 2nd gears
⇒ page 110
fork for 3rd and 4th gears
⇒ page 110
reverse gears
bling ⇒ page 168
⇒ page 110
fork for 5th and 6th gears
⇒ page 110
6 - Selector fork for reverse
gear
⇒ page 110
7 - Input shaft
⇒ page 110
bling ⇒ page 144
❑ Renew deep groove ball bearing on input shaft after each removal ⇒ page 144 .
8 - Thrust washer
❑ Place on reverse shaft.
9 - Reverse shaft
10 - Thrust washer
11 - Bleeder
❑ Connect to clutch slave cylinder.
12 - Clutch housing
13 - Input shaft seal
❑ Renew after removal ⇒ page 149
14 - O-ring
❑ Moisten with brake fluid before installing

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15 - Clutch slave cylinder with release bearing

16 - Bolt
❑ Qty. 3
❑ With compression spring and tapered ring.
❑ Assembling ⇒ page 197
19 - Differential
❑ Dismantling and assembling ⇒ page 197
Installation position of shafts and selector rods in gearbox

1 - Input shaft
2 - Output shaft for 1st to 4th gear
3 - Output shaft for 5th, 6th and reverse gears
4 - Reverse shaft
A - Selector rod for 3rd and 4th gears
B - Selector rod for 1st and 2nd gears
C - Selector rod for 5th and 6th gears
D - Selector fork for reverse gear
Reverse gear selector fork -item D- is mounted on selector rod for
5th and 6th gear -item C-.

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7.6 Assembly overview - selector forks
1 - Rubber dampers
❑ Needs to be pulled out
of selector rod/inserted
into selector rod by
hand.
fork for 1st and 2nd gears
fork for 3rd and 4th gears
fork for 5th and 6th gears
5 - Selector fork for reverse
gear
❑ Is mounted on selector
rod with selector fork for
5th and 6th gears
⇒ page 110
7.7 Renewing oil seal for selector shaft

♦ Tube - VW 423-

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♦ Extractor hook - T20143/1-
♦ Sealing grease
(ETKA) .
– Remove gearbox selector lever and gate relay lever
⇒ page 57 .
Note
If the gate relay lever cannot be removed due to the gearbox con‐
sole, take the shoe out of the gearbox selector lever.
– Remove gearbox selector lever from selector shaft.

– Pull out seal using puller hook - T20143/1- .
– Lightly oil outer circumference of new oil seal.

– Half-fill space between sealing lip and dust lip -arrow- with
sealing grease .

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– Drive in seal using tube - VW 423- .

– Install gearbox selector lever and gate relay lever
⇒ page 57 .
7.8 Removing and installing selector unit

with gearbox installed
♦ Torque wrench - VAS 6583-
♦ Release lever - 80 - 200-

♦ Sealant
♦ Allocation ⇒ Electronic parts catalogue (ETKA)
Removing
• Selector shaft is in neutral position -arrows- (shown here on a
different gearbox).
– Remove gearbox selector lever and gate relay lever
⇒ page 57 .

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– Remove gearbox neutral position sender - G701- -arrow-.
During the following step, make sure that the selector shaft is not
blocked by the angled rod -arrow-
– Remove reversing light switch - F4- -1- ⇒ page 106 .
– Unscrew locking bolt -2-.
– Then remove bolts -3-.
– Pull selector shaft with selector shaft cover -4- out of gearbox
housing.
Note
To ensure that the selector shaft -1- does not bump against the
locating bush -2- on removal, press against spring force of the
locating bush (-direction of arrow-) using removal lever - 80 -
200- .
– Cover gearbox.
Installing
different selector unit).
• Selector plates of gearbox are in neutral.
• All sealing surfaces are cleaned.
• Renew securing bolts and O-ring for sealing selector unit to
gearbox.
• The angled rod for adjusting the selector mechanism must not
be engaged

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Note
locating bush -2- on installation, press against spring force of the
200- .
– Insert selector shaft -1- in lower bearing -2- and in selector

forks -3-.
Note
For reasons of clarity, the cap is shown removed (⇒ Rep. gr. 34 ;

Gearbox housing, clutch housing; Assembly overview - gearbox
housing “item 2”)
– Now press selector shaft -1- against stop sleeve -2- in

-direction of arrow- and guide downwards with selector finger
-3- through selector forks to stop.
• Selector shaft cover -4- must be parallel to bolting surface on
gearbox housing.
• Selector shaft must move freely in gate selection direction
(upwards and downwards).
Note
If selector shaft cover is tilted relative to bolting surface, selector

shaft is not inserted in lower bearing.
– Tighten selector mechanism cover -4- using new bolts -3-.

– Screw in locking bolt -2-, ensuring that angled rod -arrow- is
not engaged.
– Install reversing light switch - F4- -1- ⇒ page 106 .

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– Gearbox for vehicles with start/stop system: insert gearbox

neutral position sender - G701- -arrow-, and tighten securing
bolt.
– Fit connectors.
– Slightly pull on connector to ensure it is properly engaged.
– Install gearbox selector lever and gate relay lever
⇒ page 57 .
– If removed, install battery ⇒ Electrical system; Rep. gr. 27 ;
Battery; Removing and installing battery .
– Connect battery and follow procedure after connecting battery
⇒ Electrical system; Rep. gr. 27 ; Disconnecting and con‐
necting battery .
Removing and installing air filter housing
Specified torques
♦ Selector unit to gearbox ⇒ page 106
7.9 Dismantling and assembling gearbox

Removing and installing gearbox housing, selector mechanism,
input shaft, output shafts, differential, selector rods and, if appli‐
cable, bevel box

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equipment required

♦ Sleeve - VW 455- or sleeve - 3160-
♦ Multi-purpose tool - VW 771-
♦ Adapter - VW 771/40-
♦ -1- Internal puller - Kukko 21/01-
♦ Separator - Kukko 17/0- -3-
♦ -4- Counter support - Kukko 22/1-

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♦ Alternative to adapter - VW 771/40- : M8 X 40 stud (locally

manufactured)
♦ Adapter - T10055/3-
♦ Support bridge - 30-211A-

♦ Thrust piece - T10143- or thrust piece - T10180-
♦ Drift - T10169-
♦ or drift - T10362- ⇒ page 139
♦ Thrust piece - T40008-

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♦ Hot-air blower - V.A.G 1416-
♦ Release lever - 80 - 200-
♦ Drip tray - V.A.G 1306-
♦ or drip tray for workshop hoist - VAS 6208-

♦ Sealant
♦ Allocation ⇒ Electronic parts catalogue (ETKA)
Dismantling gearbox
– Secure gearbox on gearbox support - VW 353- ⇒ page 103 .
– Drain gear oil from gearbox.
– Remove right flange shaft (fig. shows left flange shaft).

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– Remove clutch slave cylinder with clutch release bearing
-arrows-.
– Gearboxes for vehicles with start-stop system: remove gear‐

box neutral position sender - G701- -arrow-.
During the following step, make sure that the selector shaft is not
blocked by the angled rod -arrow-
– Move selector shaft to neutral.
– Remove reversing light switch - F4- -1-.
– Unscrew locking bolt -2-.
– Then remove bolts -3-.
– Pull selector shaft with selector shaft cover -4- out of gearbox
housing.
Note
locating bush -2- on removal, press against spring force of the
200- .

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– Unscrew securing bolt for left flange shaft by screwing 2 bolts

into flange and counterholding flange shaft with a lever.
– Remove bolts -B-, which secure gearbox housing to clutch

housing.
Note
One bolt -arrow- is located outside of bolting flange.
– Lock input shaft as follows:

The lengths of the splines on the input shaft to the gearbox differ.
– Set either installing sleeve - VW 455- over input shaft on clutch
housing
– or set sleeve - 3160- over input shaft on clutch housing.

– Then, clamp splitter -A-, e.g. -Kukko 17/0- , behind notch in
splines of input shaft.
The back side of the splitter must rest against installing sleeve -
VW 455- or sleeve - 3160- without play.
Note
The input shaft is fitted with covers made from sheet metal and
covers made from plastic.

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Retaining ring -A- has been discontinued for input shaft covers
made of plastic.
♦ -I- = sheet metal cover plate for input shaft with retaining ring
-A-
♦ -II- = plastic cover plate for input shaft without retaining ring
Sheet metal cover plate

– Remove retaining ring -A- for input shaft sealing cover.
– Pierce rubber in centre of cover -C- with a screwdriver .
Caution
Risk of damage to components beneath sealing cover.
– Pull sealing cover out of gearbox housing.

A - Counter support , e.g. -Kukko 22/1-
B - Internal puller, 8…12 mm , e.g. -Kukko 21/01-
Note
Sealing cover -1- can also be levered off carefully using a screw‐
driver -2-.

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Plastic cover plate

Carefully remove all lugs -A-. When doing this, do not damage
gearbox housing.
– Pry out sealing cover -A-.

• When doing this, ensure any sealing cover components are
removed.
Continued for all

Remove retaining ring -C- from deep groove ball bearing of input
shaft in gearbox housing as follows:
– Hold one end of retaining ring using screwdriver -A-.
– Using screwdriver -B-, lever other end out of groove in deep
groove ball bearing -direction of arrow-.
– Using screwdriver -B-, lever out securing ring further.
– Remove securing bolts -A- for gearbox housing to clutch hous‐

ing.

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– Then, screw adapter VW 771/40 into threaded hole of gearbox

housing.
As an alternative to adapter - VW 771/40- , the following tool as‐
sembly can be selected:
– Screw M8 X 40 stud (locally manufactured) into threaded hole
of gearbox housing onto stop.
– Screw adapter - T10055/3- onto stud as far as stop.
Continued for all
– Heat gearbox housing using hot air blower , e.g. -V.A.G 1416-
in vicinity of bearing seat for deep groove ball bearing for input
shaft for about 10 minutes to about 100°C.
– Using multi-purpose tool VW 771/1 , pull gearbox housing off
clutch housing in -direction of arrow-.
Note
If necessary, carefully lever off gearbox housing at protruding

shoulders along perimeter alternately using assembly lever. Be
careful not to damage sealing surfaces.
– Remove splitter -A- and installing sleeve VW 455 or sleeve -

3160- from input shaft.
To remove shafts from clutch housing, a second mechanic is re‐
quired.
– With left hand, raise differential -1-. With right hand, lift output
shaft for 1st to 4th gear together with selector rods -2-
-arrow A-.
– At same time, second mechanic lifts input shaft, reverse shaft
and output shaft for 5th and 6th gears and reverse gear -3-
together with selector rod out of clutch housing -arrow B-.
Note
After shafts are lifted, set back differential in clutch housing if

necessary.
– Remove input shaft oil seal.
Note
Renew deep groove ball bearing on input shaft after each removal
⇒ page 144 .
Assembling gearbox

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• A new deep groove ball bearing has been pressed onto the
input shaft ⇒ page 144 .
• The reverse gear selector fork -1- is mounted on selector rod
for 5th and 6th gear -2- ⇒ page 125 .
– Insert input shaft -1-, output shaft for 5th and 6th gears -2-
together with selector rod for 5th and 6th gears -3-, reverse
gear selector fork -4- and reverse shaft -5-.
• Selector jaw -arrow A- of reverse gear selector fork points to‐
wards outside of gearbox. The selector jaw -arrow B- of se‐
lector rod for 5th and 6th gears must point towards the inside
of gearbox.
– Then insert differential -1-.
Note
A second mechanic will be required for further installation of the

shafts in the clutch housing.
– Take output shaft for 1st to 4th gears -3- with selector rods
-4- in the right hand as shown in illustration.
– Lift differential slightly with left hand.
– At the same time, a 2nd mechanic must slightly lift input shaft
and output shaft for 5th and 6th gears -2- together with reverse
gear shaft.
– Insert output shaft for 1st to 4th gears in direction of -arrow-.
• The teeth of the input shaft, the output shafts and the final drive
input gear of differential must mesh.
– Then, working with second mechanic, place shafts and differ‐
ential in their bearing seats

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– Secure support bridge - 30-211A- for input shaft to clutch

housing.
Note
For clarity of illustration, clutch housing is shown turned 180°.
– Screw in bolt -A- until input shaft rises slightly.
Deep groove ball bearing of input shaft fits into gearbox housing
in only one position
There is a flat section on deep groove ball bearing and on the
bearing support for the deep groove ball bearing.
• Flats -A- on deep groove ball bearing and on bearing support
-B- in gearbox housing must line up.
– Mark these flat sections with colour.
– Transfer markings to upper area of deep groove ball bearing
and to upper area of bearing support of gearbox housing (⇒
next illustration).
– Heat gearbox housing for about 10 minutes to 100 °C in vicinity
of seat for deep groove ball bearing of input shaft using hot air
blower - V.A.G 1416- .
Note
♦ Heating is necessary to avoid damage to deep groove ball

bearing when gearbox housing is installed.
♦ Apply sealant evenly to sealing surface of clutch housing.
♦ Line up marking on deep groove ball bearing -A- with marking
on gearbox housing -B- and set gearbox housing in place.

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– Fit gearbox housing and tighten new bolts -A-, -B- and -C-.
– Install retaining ring -1- for deep groove ball bearing of input
shaft.
– Remove support bridge - 30 - 211 A- for input shaft.
– If stop sleeve for selector shaft was removed, drive it in now
onto stop of tool ⇒ page 139
– Turn gearbox in repair stand with opening for selector shaft

upwards.
different selector unit).
• Selector plates of gearbox are in neutral.
• All sealing surfaces are cleaned.
• Renew securing bolts and O-ring for sealing selector unit to
gearbox.
• The angled rod for adjusting the selector mechanism must not
be engaged
Note
locating bush -2- on installation, press against spring force of the
200- .

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– Insert selector shaft -1- in lower bearing -2- and in selector

forks -3-.
Note
For better clarity, sealing cover ⇒ page 131 is removed in illus‐

tration.
– Now press selector shaft -1- against stop sleeve -2- in

-direction of arrow- and guide downwards with selector finger
-3- through selector forks to stop.
• Selector shaft cover -4- must be parallel to bolting surface on
gearbox housing.
• Selector shaft must move freely in gate selection direction
(upwards and downwards).
Note
If selector shaft cover is tilted relative to bolting surface, selector

shaft is not inserted in lower bearing.
– Tighten bolts -3- for selector shaft cover -4-.

Manual gearbox “with” oil filler plug
– Screw in new locking bolt -2-, ensuring that angled rod
-arrow- is not engaged.
Manual gearbox “without” oil filler plug
Fill oil through threaded hole for locking bolt -2-.
– Seal threaded hole to prevent ingress of foreign particles into
gearbox. The previously used locking bolt can be used for this
purpose.
– Do not screw in new locking bolt -2- until oil has been filled
⇒ page 99 .
Continued for all
– Install reversing light switch - F4- -1-.
– Gearbox for vehicles with start/stop system: insert gearbox

neutral position sender - G701- -arrow-, and tighten securing
bolt.

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– Drive in input shaft oil seal flush.

– Install clutch slave cylinder together with clutch release bear‐
ing ⇒ page 34 .
– Shift through all gears.
– Install sealing cover as follows:
Cover plate identification

-I- = sheet metal cover plate; secured with retaining ring -A-.
-II- = plastic cover plate; without circlip
Allocation
Receptacle for Sealing cap Driving in
cover plate
-Arrow A- = verti‐ Made of sheet metal ⇒ page 130
cally
-Arrow B- = diago‐ Plastic ⇒ page 130
nal

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Sheet metal cover plate

– Drive sealing cover plate into gearbox housing to stop of thrust
piece.
– Secure sealing cover plate with retaining ring -A-.
Plastic cover plate

– Drive sealing cover plate into gearbox housing to stop of thrust
piece.
Continued for all
• Always observe cover plate allocation ⇒ page 129 .
• Leak may occur when installed incorrectly
• Allocate sealing cover using ⇒ Electronic parts catalogue
(ETKA) .
– Install flange shafts together with springs, thrust washers and

tapered rings.
– Tighten right flange shaft countersunk bolt with socket .
Specified torques
♦ ⇒ “7.3 Assembly overview - gearbox housing and selector
♦ ⇒ “1.4 Assembly overview - clutch release mechanism”, page
18 .
♦ ⇒ “2.2 Dismantling and assembling differential”, page 197 .

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8 Gearbox housing, clutch housing

⇒ “8.1 Assembly overview - gearbox housing”, page 131
⇒ “8.2 Assembly overview - clutch housing”, page 133
⇒ “8.3 Repairing gearbox housing”, page 134
⇒ “8.4 Repairing clutch housing”, page 142
8.1 Assembly overview - gearbox housing
1 - Gearbox housing
❑ If renewed: adjust out‐
put shafts and differen‐
tial ⇒ page 206
❑ Changes in area of sup‐
port for input shaft cover
⇒ page 106
❑ Refer to the ⇒ Electron‐
ic parts catalogue (ET‐
KA) for component allo‐
cation.
2 - Sealing cap
❑ Removing ⇒ page 137
❑ Driving in ⇒ page 137
3 - Oil drain plug
❑ Specified torque
⇒ page 102
4 - Seal
❑ If fitted, renew after re‐
moval
5 - Oil filler plug
❑ A number of manual
gearboxes is not fitted
with an oil filler plug.
❑ If a gearbox without oil
filler plug has been com‐
pletely dismantled, fill oil
before reassembly.
❑ Capacity of manual
gearbox (gearbox com‐
pletely dismantled)
♦ 2.30 litres
❑ If a gearbox without oil
filler plug has been dismantled partially, fill oil after reassembly.
❑ Capacity of manual gearbox (gearbox partially dismantled)
♦ 2.15 litres
❑ Note ⇒ “5 Gear oil”, page 99
6 - Angled rod
❑ For adjusting selector mechanism ⇒ page 65
❑ Can be renewed with gearbox assembled
8. Gearbox housing, clutch housing 131

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7 - Bearing bush
❑ For selector shafts
8 - Stop sleeve
❑ Pressing out with gearbox dismantled ⇒ page 139
❑ Pressing out with gearbox assembled ⇒ page 139
❑ Stop sleeve identification ⇒ page 139
❑ Drive in ⇒ page 140 to ⇒ page 140
9 - Needle bearing
❑ For reverse shaft
❑ Pressing in ⇒ page 141 .
10 - Tapered roller bearing outer race
❑ For output shaft for 5th, 6th and reverse gears
❑ If renewed, adjust output shaft for 5th, 6th and reverse gears ⇒ page 182
11 - Shim
❑ Adjustment overview ⇒ page 206
❑ For output shaft for 1st to 4th gears
❑ If renewed: adjust output shaft for 1st through 4th gears ⇒ page 177
13 - Shim
❑ For differential
❑ If renewed, adjust differential ⇒ page 201
15 - Shim
16 - Bearing bush
17 - Plug
❑ Driving out ⇒ Fig. ⇒ page 141
18 - Seal
❑ For left flange shaft

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8.2 Assembly overview - clutch housing
1 - Bearing bush
❑ For selector shafts
2 - Needle bearing
❑ For reverse shaft
❑ Pressing in
⇒ page 143 .
3 - Dowel sleeve
❑ Qty. 2
4 - Clutch housing
❑ If renewed: adjust out‐
put shafts and differen‐
tial ⇒ page 206
5 - Cap
❑ Not fitted in all clutch
housings
6 - Input shaft seal
⇒ page 111
7 - Seal
❑ For right flange shaft
⇒ page 191
8 - Washer
❑ Installation position:
shoulder on inner circumference faces seal
❑ If renewed, adjust differential ⇒ page 201
10 - Oil deflector ring
❑ Installation position: shoulder on hole faces output shaft
❑ If renewed: adjust output shaft for 1st through 4th gears ⇒ page 177
❑ If renewed, adjust output shaft for 5th, 6th and reverse gears ⇒ page 182
13 - Washer

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❑ Always 0.65 mm thick
14 - Cylindrical roller bearing
❑ For input shaft
15 - Magnet
❑ Held in place by housing joint surface
8.3 Repairing gearbox housing

equipment required
♦ Drift sleeve - VW 244 B-

♦ Pressure plate - VW 401-
♦ Press tool - VW 407-
♦ Tube - VW 416 B-

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♦ Guide - VW 436A-
♦ Guide - VW 439-
♦ Guide pin - 10 - 15-

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♦ Drift - 3264-
♦ Assembly tool - 3290-
♦ Drift - T10168-
♦ Drift - T10169- or drift - T10362- ⇒ page 139

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♦ -1- Internal puller -

Kukko 21/2-

Kukko 21/4-
♦ -4- Counter support -
Kukko 22/2-
♦ Thread adapter from
counter support -
Kukko 22/1-
Removing sealing cover
-A-
– Pierce centre of seal‐
ing cover using
screwdriver -B- and
lever out cover
-in direction of arrow-
.
Driving in sealing cover to stop
Removing angled rod for selector shaft

– Break off angled rod in released position.
– Insert a screwdriver -A- into hole for angled rod -B-
– Lever out angled rod in -direction of arrow-.

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Installation position of angled rod

• Marking on angled rod -arrow- must face clutch slave cylinder
connection -1-.
• Dimension -a- must be about 45°.
Drive in angled rod for selector shaft -arrow- to stop of tool.
Note
Angled rod must be released while it is being driven in.
Pulling out selector rod bearing bush

A - Internal puller, 14.5…18.5 mm , e.g. -Kukko 21/2-
B - Counter support , e.g. -Kukko 22/2-
Driving in selector shaft bearing bush to stop of tool

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Pressing stop sleeve -A- out of gearbox housing

– Place gearbox housing on thrust plates - VW 401- and -VW
402- in such a way that dowel sleeves in gearbox housing are
not damaged.
Driving stop sleeve out of assembled gearbox using guide pin -

10 - 15-
• Remove locking screw and selector shaft.
– Turn gearbox so that stop sleeve does not fall in gearbox.
Stop sleeve identification
Following stop sleeves can be installed:

Stop sleeve with shoulder -arrow 1-
Stop sleeve without shoulder -arrow 2-
Stop sleeve
With shoulder Without shoulder
Various versions
Driving in ⇒ page 140 Stop sleeve “02T” Stop sleeve “02Q”
⇒ page 140 ⇒ page 140
Allocate components using ⇒ Electronic parts catalogue (ETKA) .

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Stop sleeve “02T” and stop sleeve “02Q”

Drive in stop sleeve “02T” ⇒ page 140 .
Drive in stop sleeve “02Q” ⇒ page 140 .
Drive in stop sleeve with shoulder and stop sleeve “02Q” without
shoulder
• Clutch housing bolted to gearbox housing.
Driving in stop sleeve to stop
Drive in stop sleeve “02T” without shoulder

• Clutch housing bolted to gearbox housing.
Driving in stop sleeve to stop
Pulling reverse shaft needle bearing out of gearbox housing

A - Internal puller, 23.5…30 mm , e.g. -Kukko 21/4-
B - Counter support , e.g. -Kukko 22/2-
Note
The needle bearing is destroyed during removal and must be re‐

newed.

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Pressing needle bearing -A- into gearbox housing

– Before pressing in, place reverse shaft thrust washer -B- on
needle bearing.
– Support gearbox housing with tube - VW 416 B- directly below
bearing support.
Pulling out selector shaft bearing bush

– Use thread adapter from counter support - Kukko 22/1-
-arrow-.
– Hold spindle of assembly tool - 3290- securely and turn nut
-B-.
A - Internal puller, 14.5…18.5 mm , e.g. -Kukko 21/2-
Driving in selector shaft bearing bush -A- to stop of tool.
Driving out plug -1-

– Drive in plug -1- outwards from inside gearbox housing.

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Driving in plug -1-

– Drive in sealing plug to dimension -a-, approx. 3 mm below
upper edge of housing, using punch - 3264- .
8.4 Repairing clutch housing

equipment required

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♦ Drift - T10168-
Pulling out selector rod bearing bush
B - Internal puller, 14.5…18.5 mm , e.g. -Kukko 21/2-
Driving in selector shaft bearing bush to stop of tool
Pulling needle bearing out of clutch housing

B - Internal puller, 23.5…30 mm , e.g. -Kukko 21/4-
Note
The needle bearing is destroyed during removal and must be re‐

newed.
Pressing needle bearing -A- into clutch housing

– Before pressing in, place reverse shaft thrust washer -B- on
needle bearing.

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35 – Gears, shafts
1 Input shaft
⇒ “1.1 Assembly overview - input shaft”, page 144
⇒ “1.2 Dismantling and assembling input shaft”, page 145
⇒ “1.3 Renewing input shaft seal”, page 149
1.1 Assembly overview - input shaft
Note
♦ Heat gears to about 100°C with the inductive heater - VAS 6414- before installing. Wear protective gloves
when doing this.
♦ Install all bearings on input shaft with gear oil.
♦ Renew deep groove ball after each removal.
1 - Retaining ring
❑ For deep groove ball
bearing of input shaft
⇒ page 116
2 - Gearbox housing
3 - Retaining ring
❑ If deep groove ball bear‐
ing and input shaft are
renewed, redetermine
⇒ page 148 .
4 - Deep groove ball bearing
❑ Pressing off
⇒ page 147
⇒ page 148
❑ Pressing on
⇒ page 148
5 - Gear wheel for 5th gear
❑ Offered as replacement
part together with input
shaft
❑ Pressing off
⇒ page 147
❑ Installation position: pe‐
ripheral groove -arrow-
faces deep groove ball
bearing.
❑ Pressing on
⇒ page 147
6 - Input shaft
❑ With gear wheels for
3rd, 4th and 6th gears
144 Rep. gr.35 - Gears, shafts

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7 - Cylindrical roller bearing

❑ With retaining ring
❑ Installation position: retaining ring in bearing faces input shaft
8 - Clutch housing
1.2 Dismantling and assembling input shaft

equipment required

♦ Press tool - VW 408 A-
♦ Thrust piece - VW 454-
1. Input shaft 145

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♦ Tube - 2040-
♦ Thrust piece - 32 - 111-
♦ Inductive heater - VAS 6414-

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♦ -3- Splitter 22...115 mm - Kukko 17/2-

♦ Feeler gauge
Dismantling input shaft
– Remove retaining ring for deep groove ball bearing.
Pressing off deep groove ball bearing
– Apply splitter -A- to peripheral groove for retaining ring in deep
groove ball bearing.
A - Splitter 22 … 115 mm , e.g. -Kukko 17/2-
– Deep groove ball bearing and gear wheel for 5th gear can also
be pressed off together as a unit. To do this, fit splitter -A-
beneath gear wheel for 5th gear, as shown in illustration.
Pressing off 5th gear wheel

Assembling input shaft
Heating and pressing on gear wheel for 5th gear

• Groove -arrow- in gear wheel must face upwards.
1. Input shaft 147

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Installation position of deep groove ball bearing/pressing on deep

groove ball bearing
• Installation position of deep groove ball bearing: Groove for
retaining ring points upwards -arrow A-. Shoulder -arrow B-
must face gear wheel for 5th gear.
– Determine retaining ring for deep groove ball bearing on input
shaft ⇒ page 148 and install.
Determining thickness of retaining ring

– Insert a 1.86 mm thick retaining ring -A- in groove of input shaft
and press upwards.
– Measure distance between deep groove ball bearing -B- and
installed retaining ring -A- using feeler gauge -C-.
– Remove retaining ring (only used for measuring purposes).
– Determine retaining ring from table.
Note
Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐

KA) .
The following securing clips are available:

Measured value Retaining ring thick‐ Axial play (mm)
(mm) ness (mm)
0.01 … 0.05 1.86 0.01 … 0.05
0.05 … 0.07 1.89 0.01 … 0.05
0.07 … 0.10 1.92 0.01 … 0.05
0.10 … 0.13 1.95 0.01 … 0.05
0.13 … 0.16 1.98 0.01 … 0.05
Pulling cylinder roller bearing out of clutch housing

– When pulling out, squeeze together retaining ring -arrow- of
cylindrical roller bearing, using pliers -C-.
B - Internal puller, 30 … mm , e.g. -Kukko 21/5-

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Pressing cylindrical roller bearing into clutch housing

– When pressing in, squeeze together retaining ring -arrow- of
cylinder 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.
1.3 Renewing input shaft seal

♦ Extractor hook - T20143/1-
♦ Sealing grease
(ETKA) .
– Remove manual gearbox.
– Remove clutch slave cylinder together with clutch release
bearing ⇒ page 34 .
1. Input shaft 149

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– Lever out input shaft seal.
Note
Do not damage oil seal running surface on input shaft.
– Half-fill space between sealing lip and dust lip of new seal with
sealing grease .
– Lightly moisten outer circumference of oil seal with gear oil.
– Drive in input shaft oil seal flush.

– Install clutch slave cylinder together with clutch release bear‐
ing ⇒ page 34 .
– Install manual gearbox.

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2 Output shaft
⇒ “2.1 Assembly overview - output shaft”, page 151
⇒ “2.2 Dismantling and assembling output shaft”, page 156
⇒ “2.3 Adjusting output shaft”, page 177
2.1 Assembly overview - output shaft

⇒ “2.1.1 Assembly overview - output shaft for 1st to 4th gears”,
page 151
⇒ “2.1.2 Assembly overview - output shaft for 5th, 6th and reverse
gears”, page 154
2.1.1 Assembly overview - output shaft for 1st to 4th gears
Note
♦ Heat tapered roller bearing inner races and synchro-hub to about 100 °C with the inductive heater - VAS
6414- before installing. Wear protective gloves when doing this.
♦ If output shaft or tapered roller bearings have been renewed, adjust output shaft ⇒ page 177 .
♦ Always renew both tapered roller bearings together as a set.
1 - Clutch housing
2 - Oil deflector ring
3 - Dished washer
❑ Pressing in
⇒ page 160 .
4 - Tapered roller bearing outer
race
❑ Pressing in
⇒ page 161 .
5 - Tapered roller bearing inner
race
❑ Pressing off
⇒ page 161
❑ Pressing on
⇒ page 161
6 - Output shaft
❑ For 1st through 4th
gears
❑ Adjusting ⇒ page 177
7 - Needle bearing
❑ For 2nd gear
2nd gear
9 - Inner ring for 2nd gear
❑ Check lugs for scoring
⇒ page 164
❑ Checking synchro-ring,
2. Output shaft 151

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outer ring and inner ring together for wear ⇒ page 164
10 - Outer bearing race for 2nd gear
❑ Check for scoring or signs of abnormal wear
❑ Checking synchro-ring, outer ring and inner ring together for wear ⇒ page 164
11 - Synchro-ring for 2nd gear
❑ Check inner surface for scoring and radial contact scoring.
12 - Locking collar with synchro-hub for 1st and 2nd gears
❑ After removing retaining ring, press off with 2nd gear synchromeshed gear ⇒ page 163
❑ Dismantling ⇒ page 165
❑ Assembling locking collar and synchro-hub ⇒ page 165 and ⇒ page 165
❑ Pressing on ⇒ page 165
13 - Retaining ring
14 - Synchro-ring for 1st gear
15 - Outer ring for 1st gear
16 - Inner ring for 1st gear
17 - Needle bearing
❑ For 1st gear
18 - Synchromeshed gear for 1st gear
❑ Place on output shaft ⇒ page 166
19 - Thrust washer
❑ For 1st and 4th gear
❑ Qty. 2
❑ Insert lugs of thrust washer in holes of output shaft
❑ Not installed on reinforced gearboxes.
20 - Retaining ring
❑ Secures thrust washers for 1st and 4th gears in position on output shaft.
❑ Not installed on reinforced gearboxes.
21 - Needle bearing
❑ For 4th gear
22 - Synchromeshed gear for 4th gear
23 - Synchro-ring for 4th gear
❑ Made from sheet brass or steel metal
❑ Check for wear ⇒ page 166

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24 - Locking collar with synchro-hub for 3rd and 4th gears

❑ After removing retaining ring, pull off with 4th gear synchromeshed gear ⇒ page 163 .
❑ Installation position, locking collar and synchro-hub ⇒ page 167
25 - Retaining ring
26 - Synchro-ring for 3rd gear
27 - Outer ring for 3rd gear
28 - Inner ring for 3rd gear
29 - Needle bearing
❑ For 3rd gear
30 - Synchromeshed gear for 3rd gear
❑ Place on output shaft ⇒ page 168
31 - Tapered roller bearing inner race
❑ Pulling off ⇒ page 162
32 - Retaining ring
❑ If tapered roller bearing inner race and output shaft are renewed, redetermine ⇒ page 162 .
34 - Shim
❑ Determining thickness ⇒ page 177
2. Output shaft 153

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2.1.2 Assembly overview - output shaft for 5th, 6th and reverse gears
Note
♦ Heat tapered roller bearing inner races and synchro-hub to about 100 °C with the inductive heater - VAS
6414- before installing. Wear protective gloves when doing this.
♦ If output shaft or tapered roller bearings have been renewed, adjust output shaft ⇒ page 182 .
1 - Clutch housing
2 - Washer
❑ Always 0.65 mm thick
race
❑ Pressing in
⇒ page 173 .
race
❑ Pressing on
⇒ page 177
5 - Output shaft
❑ For 5th, 6th and reverse
gears
❑ Adjusting ⇒ page 182
6 - Reverse gear synchro-hub
❑ Pressing off
⇒ page 174
⇒ page 175
❑ Pressing on
⇒ page 175
7 - Retaining ring
8 - Reverse gear locking collar
❑ With synchro-ring
9 - Needle bearing
❑ For synchromeshed
gear for reverse gear
10 - Synchromeshed gear for reverse gear
11 - Sleeve
❑ Press off together with synchromeshed gear for reverse gear ⇒ page 174
❑ Installation position: wide shoulder of sleeve faces synchromeshed gear for reverse gear
12 - Retaining ring
13 - Needle bearing
❑ For 6th gear

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16 - Locking collar with synchro-hub for 5th and 6th gears
❑ After removing circlip, press off with 6th gear synchromeshed gear ⇒ page 174
17 - Retaining ring
18 - Needle bearing
❑ For 5th gear
21 - Tapered roller bearing inner race
22 - Retaining ring
❑ If tapered roller bearing inner race and output shaft are renewed, redetermine ⇒ page 177 .
24 - Shim
❑ Determining thickness ⇒ page 182
26 - Spring
27 - Sliding sleeve
28 - Synchro-hub
29 - Locking piece
❑ Qty. 3
2. Output shaft 155

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2.2 Dismantling and assembling output

shaft
⇒ “2.2.1 Dismantling and assembling output shaft for 1st through
4th gears”, page 156
⇒ “2.2.2 Dismantling and assembling output shaft for 5th, 6th and
reverse gears”, page 168
2.2.1 Dismantling and assembling output shaft for 1st through 4th gears

equipment required

♦ Press tool - VW 408A-
♦ Tube - VW 415A-

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2. Output shaft 157

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♦ Tube - VW 516-
♦ Tube - VW 519-
♦ Thrust plate - 40-105-

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♦ Drift sleeve - 40-20-

♦ Drift sleeve - 40-21-
♦ Supplementary set for engine and gearbox support - VW 540/1
B-
♦ Tapered roller bearing puller - V.A.G 1582-
♦ Grip tool - V.A.G 1582/7-
2. Output shaft 159

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♦ Inductive heater -
VAS 6414-

Kukko 21/7-

Kukko 21/8-
♦ Puller - Kukko 18/2-
-2-
♦ Separator - Kukko
17/2- -3-
Kukko 22/2-
Pulling dished washer
-A- out of output shaft
Pressing dished washer into output shaft

Dimension “a” = 2 mm

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Press off tapered roller bearing inner race on side facing clutch
housing
A - Splitter, 22 … 115 mm , e.g. -Kukko 17/2-
Press on tapered roller bearing inner race on side facing clutch

housing
Pulling tapered roller bearing outer race out of clutch housing

Pressing tapered roller bearing outer race into clutch housing

– Support clutch housing with drift sleeve - 40-20- directly below
bearing support.
2. Output shaft 161

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Pulling off tapered roller bearing inner race on side facing gearbox
housing
Before installing tapered roller bearing puller observe the follow‐
ing:
– Remove retaining ring for tapered roller bearing inner race on
side facing gearbox housing.
– Insert press tool - VW 431- into output shaft and place thrust
plate - 40-105- on that.
Press on tapered roller bearing inner race on side facing gearbox

housing
– Determine and install retaining ring ⇒ page 162 .

– Determine the thickest circlip which will just fit and install it.
Note
Allocate retaining rings using ⇒ Electronic parts catalogue (ET‐

KA) .
The following securing clips are available:

Thickness (mm)
1.79 1.83 1.86 1.89
1.92 1.95 1.98
Pulling outer race for tapered roller bearing out of gearbox hous‐
ing

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Pressing tapered roller bearing outer race into gearbox housing

– Fit shim under outer race.
– Support gearbox housing with thrust piece - 2050- below bear‐
ing support.
Dismantling output shaft
Note
housing ⇒ page 162 .
Pulling off synchro-hub and locking collar for 3rd and 4th gears
with synchromeshed gear for 4th gear
– First remove retaining ring.
A - Puller , e.g. -Kukko 18/2-
B - Splitter, 22 … 115 mm , e.g. -Kukko 17/2-
– Then remove retaining ring ⇒ Item 20 (page 152) and thrust
washers ⇒ Item 19 (page 152) .
– Next step is to remove synchromeshed gear for 1st gear with
synchro-rings.
Pressing off locking collar and synchro-hub for 1st and 2nd gears
After removing retaining ring, press off synchromeshed gear for
2nd gear together with locking collar and synchro-hub.
Assembling output shaft
Note
Heat inner races of tapered roller bearings and synchro-hub with

the inductive heater - VAS 6414- to approx. 100°C and press them
in to stop so there is no axial clearance.
2. Output shaft 163

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Checking synchro-ring for 1st, 2nd and 3rd gears for wear to‐
gether with outer and inner races
– Check inner contact surface of synchro-ring -arrow- for scoring
and radial contact scoring; if necessary, renew inner race,
outer race and synchro-ring
– Place inner ring, outer ring and synchro-ring on cone of syn‐
chromeshed gear.
– Press down and simultaneously rotate synchro-ring so that
rings seat properly.
– Measure gap size -a- at 3 points offset by 120° using feeler
gauge.
– Make a note of average value.
Gap -a- Installation dimen‐ Wear limit
sion
1st and 2nd gears 1.2 … 1.8 mm 0.8 mm

sion
3rd gear 1.2 … 2.0 mm 0.8 mm
Note
Always renew inner ring, outer ring and synchro-ring together.
– Set 2nd gear synchromeshed gear with needle bearing in

place.
Installation of outer ring, inner ring and synchro-ring for 2nd gear
– Place inner ring -A- on synchromeshed gear for 2nd gear.
Lugs -1- point away from synchromeshed gear.
– Fit outer ring -B-.
Lugs -2- engage in notches -3- of synchromeshed gear.
– Fit synchro-ring -C-.
Larger notches -4- engage in lugs -1- of inner ring -A-.

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Dismantling and assembling locking collars and synchro-hubs of

1st and 2nd gears as well as 3rd and 4th gears
1- Spring
2- Locking piece
3- Sliding sleeve
4- Synchro-hub
– Slide locking collar over synchro-hub.
In 3rd and 4th gear, wide collar of synchro-hub and, if present,
shoulder on locking collar point in one direction.
Notches for locking pieces in synchro-hub and locking collar must
align.
Assembling locking collars and synchro-hubs for 1st and 2nd

gears as well as 3rd and 4th gears
Locking collar has been pushed over synchro-hub.
– Fit locking pieces and install springs offset 120°. Angled end
of spring must locate in hollow locking piece.
Installation position of locking collar and synchro-hub for 1st and

2nd gear
Identification groove -arrow 1- and narrow collar -arrow 2- of syn‐
chro-hub face 1st gear.
Heating and pressing on locking collar and synchro-hub for 1st

and 2nd gears
Pins -A- of synchro-ring engage in notches -B- of synchro-hub.
– Install retaining ring.
2. Output shaft 165

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Installation of synchro-ring outer ring and 1st gear inner ring

– Insert synchro-ring -A- in synchro-hub for 1st gear and 2nd
gear.
Lugs -1- engage in notches -2- of synchro-hub.
– Insert outer ring -B- into synchro-ring.
Lugs -3- point away from synchro-ring.
– Insert inner ring -C- into outer ring.
Lugs -4- engage in larger notches -5- of synchro-ring -A-.
Install synchromeshed gear for 1st gear with needle bearing

• Synchro-ring -1- is located with lugs -arrow A- in notches of
synchro-hub -2-.
Pins -arrows B- of outer ring engage in notches -arrows C- of
synchromeshed gear -3-.
– Insert thrust washers for 1st and 4th gears into output shaft
⇒ Item 19 (page 152) and ⇒ Item 20 (page 152) .
– Then fit synchromeshed gear for 4th gear with needle bearing.
Checking synchro-ring for 4th gear for wear

-A- = Synchro ring made from brass
sion
4th gear 1.0 … 1.7 mm 0.5 mm
-B- = Synchro ring made from sheet steel

sion
4th gear 1.3 … 2.4 mm 0.8 mm
– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
gauge.

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Installation position of locking collar with synchro-hub for 3rd and

4th gears
Wider shoulder of synchro-hub -arrow- faces 3rd gear.
– Place 4th gear synchro-ring on 4th synchromeshed gear.
Heat and press on synchro-hub with locking collar for 3rd and 4th
gears
– Turn synchro-ring for 4th gear so that grooves align with lock‐
ing pieces.
Installation of synchro-ring outer ring and 3rd gear inner ring

– Insert synchro-ring -A- in synchro-hub for 3rd gear and 4th
gear.
Lugs -1- engage in notches -2- of synchro-hub.
– Insert outer ring -B- into synchro-ring.
Lugs -3- point away from synchro-ring.
– Insert inner ring -C- into outer ring.
Lugs -4- engage in larger notches -5- of synchro-ring -A-.
2. Output shaft 167

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Install synchromeshed gear for 3rd gear with needle bearing

• Synchro-ring -1- is located with lugs -arrow A- in notches of
synchro-hub -2-.
Pins -arrows B- of outer ring engage in notches -arrows C- of
synchromeshed gear -3-.
Note
♦ Press on tapered roller bearing inner race ⇒ page 162 .

♦ Determine retaining ring for tapered roller bearing inner race
⇒ page 162 .
2.2.2 Dismantling and assembling output shaft for 5th, 6th and reverse gears

equipment required


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♦ Tube - VW 415 A-

♦ Mounting rail - VW 457-
2. Output shaft 169

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♦ Installing sleeve - VW 455-
♦ Thrust pad - VW 510-
♦ Tube - VW 516-
♦ Tube - VW 519-
♦ Thrust plate - 30 - 11-

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♦ Thrust plate - 40 - 105-

♦ Drift sleeve - 40 - 20-
♦ Tube - 3296-
♦ Grip tool - V.A.G 1582/4-
2. Output shaft 171

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♦ Grip tool - V.A.G

1582/7-
♦ Inductive heater -
VAS 6414-

Kukko 21/7-
♦ Separator - Kukko
17/2- -3-
Kukko 22/2-
Pulling tapered roller
bearing outer race out of
clutch housing
A - Counter support , e.g.
-Kukko 22/2-
B - Internal puller, 46…
58 mm , e.g. -Kukko
21/7-

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Note
After pulling out, check

shim for damage and re‐
new if necessary.

– Fit shim under outer race.
– Support clutch housing with drift sleeve - 40 - 20- directly below
bearing support.
ing

– Support gearbox housing with thrust piece - 2050- below bear‐
ing support.
Dismantling output shaft
housing
Before installing tapered roller bearing puller observe the follow‐
ing:
– Remove retaining ring for tapered roller bearing inner race on
side facing gearbox housing.
– Place press tool - VW 431- and thrust plate - 40-105- onto
output shaft.
2. Output shaft 173

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Pressing off synchro-hub and locking collar for 5th and 6th gears
with synchromeshed gear for 6th gear
Pressing off sleeve -A- together with synchromeshed gear for re‐
verse gear
Pressing off reverse gear synchro-hub

Pulling off tapered roller bearing inner race on side facing clutch
housing
– Before setting up pulling device, set thrust plate - 30 - 11- on
output shaft.
Assembling output shaft
Note
Heat inner races of tapered roller bearings and synchro-hub with

the inductive heater - VAS 6414- to approx. 100°C and press them
in to stop so there is no axial clearance.

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Installation position of reverse gear synchro-hub

Stop of reverse gear locking collar -arrow A- faces teeth of output
shaft -arrow B-.
Heat reverse gear synchro-hub and press on

– Place reverse gear locking collar on reverse gear synchro-
hub.
– Put on reverse gear synchromeshed gear with needle bearing.
Pressing on sleeve -A-

Installation position: Wide collar faces reverse gear synchro‐
meshed gear.
Checking synchro-rings for 5th and 6th gear for wear

-A- = Synchro ring made from brass
sion
5th and 6th gear 1.0 … 1.7 mm 0.5 mm
-B- = Synchro ring made from sheet steel

sion
5th and 6th gear 1.2 … 2.1 mm 0.8 mm
– Press synchro-ring onto cone of synchromeshed gear and
measure gap -a- using feeler gauge.
gauge.
2. Output shaft 175

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Dismantling and assembling locking collar and synchro-hub for

5th and 6th gears
1- Spring
2- Locking piece
3- Sliding sleeve
4- Synchro-hub
– Slide locking collar over synchro-hub.
Notches for locking pieces in synchro-hub and locking collar must
align.
Assembling locking collar with synchro-hub for 5th and 6th gears
Locking collar has been pushed over synchro-hub.
– Fit locking pieces and install springs offset 120°. Angled end
of spring must locate in hollow locking piece.
– Install synchromeshed gear for 6th gear with needle bearing.
– Fit synchro-ring for 6th gear.
Pressing on locking collar and synchro-hub for 5th and 6th gears
Some locking collars have a chamfer on their outer diameter.
Installation position: The chamfer on the outer diameter of the
sliding sleeve points towards the 5th gear synchromeshed gear.
– Turn synchro-ring so that grooves align with locking pieces.
– Fit synchro-ring for 5th gear.
– Install 5th gear synchromeshed gear with needle bearing.

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Press on tapered roller bearing inner race on side facing gearbox

housing
– Determine and install retaining ring ⇒ page 177 .

– Determine the thickest circlip which will just fit and install it.
– Determine retaining ring from table. Part number ⇒ Electronic
The following retaining rings are available:
Thickness (mm)
1.79 1.89 1.98
1.83 1.92
1.86 1.95
Press on tapered roller bearing inner race on side facing clutch

housing
2.3 Adjusting output shaft

⇒ “2.3.1 Adjusting output shaft for 1st through 4th gears”,
page 177
⇒ “2.3.2 Adjusting output shaft for 5th, 6th and reverse gears”,
page 182
2.3.1 Adjusting output shaft for 1st through 4th gears
2. Output shaft 177

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equipment required

♦ Universal dial gauge bracket - VW 387-
♦ Assembly tool - VW 792-

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♦ Dial gauge - VAS 6080 A-

(Determining shim for output shaft)
It is necessary to readjust the output shaft when the following
components are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Output shaft for 1st to 4th gear or
♦ Tapered roller bearing for output shaft
Adjustment overview ⇒ page 206
2. Output shaft 179

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Prerequisites:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant .
• When taking measurements, install only the output shaft to be
measured.
– Press tapered roller bearing outer race with 1.70 mm thick
shim into gearbox housing to stop. In the process, support
gearbox housing using thrust piece - 2050- directly below
bearing support.
– Set complete output shaft for 1st to 4th gears in clutch housing.
– Fit gearbox housing in position and tighten bolts -A- as well as

-B- alternately and diagonally.

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– Fit measuring tools and secure to clutch housing using bolt

-arrow-.
– Set dial gauge (3 mm measuring range) to “0” with 1 mm pre‐
load.
– Loosen clutch housing/gearbox housing securing bolts diag‐
onally until the bolts release the gearbox housing or output
shaft.
– Read and note value on dial gauge (example: 0.14 mm).
Note
♦ If no value is indicated when clutch housing/gearbox housing

securing bolts are loosened:
♦ Fit 1.95 mm shim or, if necessary, 2.20 mm shim for the meas‐
urement instead of 1.70 mm shim.
♦ Allocate shims using ⇒ Electronic parts catalogue (ETKA) .
Determining thickness of shim

Specified bearing preload is obtained as follows:
Subtracting measured value (0.14 mm) from inserted shim
(1.70 mm).
Add a constant value for preload (0.20 mm).
Example:
Installed shim 1.70 mm
- Measured value 0.14 mm
+ Preload (constant) 0.20 mm
Shim thickness 1.76 mm
– Determine thickness of shim from table ⇒ page 177 .
– Remove gearbox housing and pull tapered roller bearing outer

race out from gearbox housing.
– Remove inserted shim (1.70 mm thick) from gearbox housing.
Table of shims
Thickness (mm)
1.45 1.75 2.05
1.50 1.80 2.10
1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
The various thicknesses make it possible to achieve the exact
shim thickness required.
– Determine part number of shim according to ⇒ Electronic
2. Output shaft 181

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– Press in tapered roller bearing outer race together with correct

shim (in example 1.75 mm). In the process, support gearbox
housing using thrust piece - 2050- directly below bearing sup‐
port.
Carrying out check measurement
• Determined shim installed.
– Fit measuring tools and secure to clutch housing using bolt

-arrow-.
load.
shaft.
– If correct shim has been selected, dial gauge will indicate a
value between 0.15 mm to 0.25 mm.
Specified torques
♦ Gearbox housing to clutch housing ⇒ page 106
2.3.2 Adjusting output shaft for 5th, 6th and reverse gears

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equipment required

♦ Assembly tool - VW 792-
2. Output shaft 183

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It is necessary to readjust the output shaft when the following
components are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Output shaft for 5th, 6th and reverse gears or
♦ Tapered roller bearing for output shaft

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Prerequisites:
• Sealing surfaces of clutch and gearbox housings must be free
of sealant .
• When taking measurements, install only the output shaft to be
measured.
– Press tapered roller bearing outer race with 1.70 mm thick
shim into gearbox housing to stop. In the process, support
gearbox housing using thrust piece - 2050- directly below
bearing support.
– Place complete 5th, 6th and reverse gear output shaft in clutch
housing.
– Fit gearbox housing in position and tighten bolts -A- as well as

-B- alternately and diagonally.
2. Output shaft 185

Polo 2014 ➤
– Fit measuring tools on clutch housing.

In case of protruding housing edges do the following:
– Fit washers with a total thickness of 8 mm underneath assem‐
bly tool - VW 792- -arrow-.
load.
shaft.
– Read and note value on dial gauge (example: 0.25 mm).
Note
♦ If no value is indicated when clutch housing/gearbox housing

securing bolts are loosened:
♦ Fit 1.95 mm shim or, if necessary, 2.20 mm shim for the meas‐
urement instead of 1.70 mm shim.
♦ Allocate shims using ⇒ Electronic parts catalogue (ETKA) .

Specified bearing preload is obtained as follows:
Subtracting measured value (0.25 mm) from inserted shim
(1.70 mm).
Add a constant value for preload (0.20 mm).
Example:
Installed shim 1.70 mm
- Measured value 0.25 mm
Shim thickness 1.65 mm
– Determine thickness of shim from table.
– Remove gearbox housing and pull tapered roller bearing outer

race out from gearbox housing.
– Remove inserted shim (1.70 mm thick) from gearbox housing.
Table of shims
Thickness (mm)
1.50 1.80 2.10
1.55 1.85 2.15
1.60 1.90 2.20
1.65 1.95 2.25
1.70 2.00
1.75 2.05
– Part numbers ⇒ Electronic Parts Catalogue (ETKA) .

Polo 2014 ➤
– Press in tapered roller bearing outer race together with correct

shim (in example 1.65 mm). In the process, support gearbox
housing using thrust piece - 2050- directly below bearing sup‐
port.
Carrying out check measurement
• Determined shim installed.
– Fit measuring tools onto clutch housing.

In case of protruding housing edges do the following:
– Fit washers with a total thickness of 8 mm underneath assem‐
bly tool - VW 792- -arrow-.
load.
shaft.
– If correct shim has been selected, dial gauge will indicate a
value between 0.15 mm to 0.25 mm.
Specified torques
2. Output shaft 187

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39 – Final drive - differential

1 Seals
⇒ “1.1 Overview of fitting locations - seals”, page 188
⇒ “1.2 Renewing left oil seal”, page 189
⇒ “1.3 Renewing right oil seal”, page 191
1.1 Overview of fitting locations - seals
1 - Seal
❑ For input shaft
⇒ page 149
2 - Seal
⇒ page 191
3 - Seal
⇒ page 189
4 - Seal
❑ Lever out with a screw‐
driver
⇒ page 108
188 Rep. gr.39 - Final drive - differential

Polo 2014 ➤
1.2 Renewing left oil seal

⇒ “1.2.1 Renewing oil seal for left flange shaft”, page 189
1.2.1 Renewing oil seal for left flange shaft

equipment required

♦ Extractor hook - VW 771/37-
1. Seals 189
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♦ Sealing grease
(ETKA) .
Removing
The drive shaft must be removed in a later step.
– Do not loosen the front flange bolt -arrow- more than 90° while
the vehicle is still standing on its wheels, or the wheel bearing
will be damaged. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft
– Remove wheel.
sulation .
– Remove drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Remove flange shaft securing bolts. To do this, screw two

bolts into flange and counterhold flange shaft using a lever.
– Remove flange shaft oil seal.

Installing

Polo 2014 ➤
– Drive in new seal to stop, being careful not to cant seal.
sealing grease .
– Insert flange shaft.

– Press flange shaft against gearbox and tighten bolt.
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
– Install coupling rod -1- to anti-roll bar ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Subframe; Assembly overview – sub‐
frame .
– Check gear oil level ⇒ page 99 .
tion .
– Attach wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres; Specified torque for wheel bolts .
Specified torque
♦ Flange shaft to gearbox ⇒ page 197
1.3 Renewing right oil seal

⇒ “1.3.1 Renewing oil seal for right flange shaft”, page 191
1.3.1 Renewing oil seal for right flange shaft
1. Seals 191
Polo 2014 ➤

equipment required
♦ Drift sleeve - 3158-


♦ Sealing grease
(ETKA) .

Polo 2014 ➤
Removing
The drive shaft must be removed in a later step.
– Do not loosen the front flange bolt -arrow- more than 90° while
the vehicle is still standing on its wheels, or the wheel bearing
will be damaged. ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft
sulation .
– Turn steering to right to full lock.
– If fitted, remove heat shield above right drive shaft -arrows-.

– Remove drive shaft ⇒ Running gear, axles, steering; Rep. gr.
– Unscrew securing bolt -B- for right flange shaft.

– Pry seal out using assembly lever.
Installing
sealing grease .
1. Seals 193
Polo 2014 ➤
– Drive in new seal to stop, being careful not to cant seal.

– Press flange shaft against gearbox and tighten bolt.
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
– If fitted, install drive shaft heat shield ⇒ Running gear, axles,

steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft heat shield .
– Check gear oil level ⇒ page 99 .
tion .
Specified torque
♦ Flange shaft to gearbox ⇒ page 197

Polo 2014 ➤
2 Differential
⇒ “2.1 Assembly overview - differential”, page 195
⇒ “2.2 Dismantling and assembling differential”, page 197
⇒ “2.3 Adjusting differential”, page 201
2.1 Assembly overview - differential
Note
♦ Heat tapered roller bearing inner races to about 100°C with the inductive heater - VAS 6414- before installing.
Wear protective gloves when doing this.
♦ If tapered roller bearings, differential cage, gearbox housing or clutch housing is renewed, adjust differential
⇒ page 201 .
1 - Gearbox housing
2 - Shim
❑ Determining thickness
⇒ page 201
race
❑ Pressing in
⇒ page 200 .
race
❑ Pressing on
⇒ page 199
5 - Differential cage
❑ With differential bevel
gears, one-piece thrust
washer, differential pin‐
ion pin and final drive
gear
❑ Removing differential
bevel gears, one-piece
thrust washer and differ‐
ential pinion pin
⇒ page 201
❑ Installing differential
bevel gears, one-piece
thrust washer and differ‐
ential pinion pin
⇒ page 201
race
2. Differential 195
Polo 2014 ➤
8 - Washer
❑ Installation position: shoulder on inner circumference faces seal ⇒ Item 10 (page 196)
9 - Clutch housing
10 - Seal
❑ 33 Nm
13 - Protective ring
❑ Lever protective ring off right flange shaft with a screwdriver, alternating sides.
❑ Install with indentation facing away from threaded hole in flange shaft
❑ Push on protective ring to stop by hand
❑ Protective ring must engage in flange shaft
14 - Compression spring for flange shaft
❑ Installed behind flange shaft
15 - Thrust washer
❑ Installation position: shoulder faces spring, lugs, if present, face tapered ring
16 - Tapered ring
❑ Installation position: taper towards differential cage
17 - Retaining ring
❑ Holds tapered ring, thrust washer and spring in position when flange shaft is removed
18 - Protective ring
❑ Pry protective ring off flange shaft with a screwdriver, alternating sides
❑ Install with indentation facing away from threaded hole in flange shaft
❑ Push on protective ring to stop by hand
❑ Protective ring must engage in flange shaft
20 - Seal

Polo 2014 ➤
2.2 Dismantling and assembling differential

equipment required

♦ Thrust plate - 40-105-
♦ Thrust plate - 3005-
♦ Tube - VW 415 A-
2. Differential 197
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♦ Tube - 3259-
♦ Tube - 3296-
♦ Tube - 3345-
♦ Grip tool - V.A.G 1582/6A-
♦ Internal puller - 1 - Kukko 21/7-
♦ Puller - 2 - Kukko 18/1-
♦ Splitter - 3 - Kukko 17/1-
♦ Counter support - 4 - Kukko 22/2-

Polo 2014 ➤
Note
♦ Heat tapered roller bearing inner race to 100 C before instal‐

ling.
♦ If tapered roller bearings, differential cage, gearbox housing
or clutch housing is renewed, adjust differential ⇒ page 201 .
Pulling tapered roller bearing outer race out of clutch housing

B - Internal puller 46 … 58 mm , e.g. -Kukko 21/7-
Note
After pulling out, renew washer.

– First insert washer.
Note
Observe installation position of washer. Shoulder on inner diam‐

eter faces seal.
Pulling off tapered roller bearing inner race

– Before setting up pulling device, set thrust plate - 40-105- on
differential housing.
Pressing on tapered roller bearing inner race
2. Differential 199
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Pulling off tapered roller bearing inner race

A - Puller , e.g. -Kukko 18/1-
B - Splitter 12 to 75 mm , e.g. -Kukko 17/1-
Pressing on tapered roller bearing inner race

Cage with tapered rollers must be easy to turn during pressing.
ing
B - Internal puller 46 … 58 mm , e.g. -Kukko 21/7-

– Support gearbox housing with tube - 3345- directly below
bearing support.

Polo 2014 ➤
Removing and installing spring pin for differential pinion pin

Removing
– Cover tapered roller bearing inner race to prevent possible
damage and ingress of metal particles.
– Drive out spring pin with chisel, inserting chisel into circum‐
ferential groove.
Installing
– Drive into differential cage to stop.
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 planet pinions offset 180° and pivot into position.
– Press in differential pinion pin -arrow A- to first planet pinion.
– Place threaded pieces -arrow B- in sun gears.
Installation position: shoulder to sun gear
– Drive differential pinion pin into final position and secure with
spring pin.
2.3 Adjusting differential
2. Differential 201
Polo 2014 ➤

equipment required

♦ End dimension plate - VW 385/17-
♦ Thrust plate - 3005-

Polo 2014 ➤
♦ Tube - 3259-
♦ Tube - 3345-
♦ 30 mm dial gauge extension
It is necessary to readjust the differential when the following com‐
ponents are renewed:
♦ Gearbox housing
♦ Clutch housing
♦ Differential cage or
♦ Tapered roller bearing of differential
2. Differential 203
Polo 2014 ➤
– Press tapered roller bearing outer race with shim

⇒ Item 8 (page 196) into clutch housing.
Note
♦ Observe installation position of shim.

♦ Shoulder on inner circumference faces seal in clutch housing.
– Press outer ring/taper roller bearing, without shim, into gear‐

box housing.
– Fit differential into clutch housing.
– Fit gearbox housing and tighten 5 bolts
⇒ Item 13 (page 107) and ⇒ Item 14 (page 107) .
– Press differential in direction of clutch housing while turning it
8 times.
– Press differential in direction of gearbox housing while turning
it 8 times.
– Fit measuring tools onto gearbox housing.
– Set dial gauge to “0” with 1 mm preload.

A - 30 mm dial gauge extension
– Move differential up and down. Read and note play indicated
on dial gauge. (Example: 0.70 mm)
The specified bearing preload is obtained by adding a constant
value for preload (0.25 mm) to the reading obtained.
Example:
Measured value 0.70 mm
Thickness of shim = 0.95 mm
– Remove gearbox housing.

Polo 2014 ➤
– Pulling outer race for tapered roller bearing out of gearbox

housing.
– Determine part number of shim according to ⇒ Electronic
– Insert shim of determined thickness.
The following shims are available:
Shim thickness (mm)
0.65 0.85 1.05 1.25
0.70 0.90 1.10
0.75 0.95 1.15
0.80 1.00 1.20
If the size of shim required is larger than those listed in the table,
insert two shims totalling the correct figure. When using two
shims, install the thicker one first.
– Press in outer ring again and bolt on gearbox housing

⇒ page 106 .
Specified torques
2. Differential 205
Polo 2014 ➤
3 Adjustment overview
Note
It is necessary to readjust output shaft for 1st through 4th gear,

output shaft for 5th, 6th and reverse gear or differential only if
components have been renewed which have a direct effect on the
adjustment of the gearbox. To prevent unnecessary adjustments,
refer to the following table:
To be adjusted:
Output shaft Output shaft Differential
for 1st to 4th for 5th, 6th ⇒ page 201
gears and reverse
⇒ page 177 gears
⇒ page 182
Parts renewed: Gearbox housing x x x
Clutch housing x x x
Output shaft for 1st to 4th gear x
Output shaft for 5th, 6th and reverse x
gears
Differential x
Tapered roller bearings for 1st to x
4th gear output shaft
Tapered roller bearings for 5th, 6th x
and reverse gear output shaft
Tapered roller bearing for differen‐ x
tial

Volkswagen Workshop Manual (6-Speed Manual Gearbox 0A8)

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Volkswagen Workshop Manual (6-Speed Manual Gearbox 0A8)

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Service

Service Department. Technical Information

35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

1.1 Safety precautions when working on ve‐

Injury hazard as a result of automatic engine start in vehicles

2.1 Gearbox identification

Manual gearbox 0A8 -arrow 2-.

Codes and production date of gearbox -arrow-

The gearbox code also appears on the vehicle identification

2 Rep. gr.00 - Technical data

3.1 Allocation gearbox - engine

3.2.1 Capacity, manual gearbox

3.3 Calculation of gear ratios

Volkswagen Technical Site: https://vwts.ru 3. Technical data 3

4 Overview - power transmission

4 Rep. gr.00 - Technical data

4. Overview - power transmission 5

5.1 Overview of fitting locations - electrical

5.1.1 Overview of fitting locations – electrical components, manual gearbox

1 - Gearbox neutral position

5.1.2 Overview of fitting locations – electrical

6 Rep. gr.00 - Technical data

6.1 General repair instructions

♦ Renew retaining rings.

8 Rep. gr.00 - Technical data

♦ Do not interchange. When reusing synchro-rings, always fit to

1.1 Overview of fitting locations – clutch mechanism

10 Rep. gr.30 - Clutch

1.2 Assembly overview - pedal cluster

12 Rep. gr.30 - Clutch

1.3 Assembly overview - clutch hydraulics

1.3.1 Assembly overview - clutch hydraulics, left-hand drive

1 - Clutch slave cylinder

14 Rep. gr.30 - Clutch

1.3.2 Assembly overview - clutch hydraulics, right-hand drive

16 Rep. gr.30 - Clutch

1.4 Assembly overview - clutch release mechanism

1 - Clutch slave cylinder with

Use compressed air to clean hole. If

18 Rep. gr.30 - Clutch

Release bearing with additional plastic washer

1.5 Removing and installing bearing bush

– Turn plunger of clutch master cylinder so that recesses -1- or

1.6 Checking clutch master cylinder and

1.7 Removing and installing clutch position

20 Rep. gr.30 - Clutch

An insulation mat is installed in conjunction with some engines.

Continued for all

– If fitted, fold insulation mat in the sequence -1, 2, 3- around

1.8 Removing and installing over-centre

– Insert over-centre spring from side and from below, adjacent

– Now position over-centre spring on mounting lug of clutch

22 Rep. gr.30 - Clutch

♦ The over-centre spring must be located directly in the mount‐

– Press clutch pedal in operating position, and push new pivot

1.9 Removing and installing extension

1.10 Removing and installing clutch pedal

1.10.1 Removing and installing clutch pedal,

Remove bearing shaft for clutch pedal:

-1- = 10 mm hexagon bit

1.10.2 Removing and installing clutch pedal,

24 Rep. gr.30 - Clutch