02X, 6-Speed Four-Wheel Drive M/T

Clutch release mechanism, servicing, 02X, 6-Speed Four-Wheel Drive M/T





Special tools, testers and auxiliary items required
^ Thrust plate VW 401
^ Thrust disc VW 412
^ Thrust tube VW 454
^ Tube 2040
^ Torque wrench V.A.G 1331
^ - 1 - Internal puller Kukko 21/4
^ - 4 - Countersupport Kukko 22/1
^ Locking fluid AMV 185 101 A1
^ Sealing grease G 052 128 A1
^ Copper grease Z 381 351 TE
^ Adhesive AMV 195 KD1 01





1 - Release bearing
^ Do not wash out; wipe clean only
^ Replace bearings if noisy
^ Servicing release bearing with glued plastic ring
^ Checking release bearing with mechanically attached plastic ring
^ Replace if running mark (groove) is too deep
^ Retainer tabs on release bearing must engage in release lever

2 - TORX bolt, 35 Nm
^ 3x
^ Apply locking fluid AMV 185 101 A1 when installing

3 - Clutch release lever
^ Before installing, lubricate area which makes contact with operating rod of slave cylinder with copper grease Z381351TE.

4 - Retaining spring
^ Secure to clutch release lever

5 - Guide sleeve
^ Installation position: Oil drain hole points downward.
^ Before removing and installing, cover input shaft splines with a shrink-fit hose to protect oil seal.

6 - Seal
^ For input shaft
^ Pack space between sealing lip and dust lip half full with sealing grease G052128 A1.

7 - O-ring
^ Always replace

8 - Convex washer

9 - Intermediate piece
^ Installation position: insert locating element between ribs of housing

10 - Ball head stud
^ Lubricate with MoS 2 grease.

11 - Transmission

12 - Slave cylinder
^ Do not operate clutch pedal after slave cylinder has been removed.
^ Tighten bleeder valve to 4.5 Nm.
^ When installing push in until the securing bolt can be installed.

13 - Hex socket head bolt - 23 Nm
^ Self-locking
^ Replace

14 - Bracket
^ For line/hose assembly
^ Bolt to transmission with slave cylinder

15 - Operating rod
^ Lubricate end of operating rod with copper grease Z381351TE.





Checking and servicing release bearing with glued plastic ring

Identification: inner side of plastic ring has three tabs - arrows -.
The plastic ring - arrows - may come loose from the release bearing when the transmission or release bearing is removed. The release bearing does not have to be replaced if this happens.
- Before installing the transmission, glue loose plastic ring back onto bearing with adhesive AMV195KD101.

Three square tabs - arrows - of the plastic ring engage in recesses of the bearing ring.
^ The release bearing must be replaced if the groove worn on the plastic ring is deeper than 0.8 mm.





Checking release bearing with mechanically attached plastic ring
Identification: retaining tabs around plastic ring - arrows -.
^ The release bearing must be replaced if the plastic ring - 1 - has come loose.
^ The release bearing - 3 - must be replaced if the groove - arrow2 - worn on the plastic ring - 1 is deeper than 0.8 mm.





Pulling oil seal out of guide sleeve
A - Counter-support, e.g. Kukko 22/1
B - Internal puller 23.5 to 30 mm, e.g. Kukko 21/4





Pressing oil seal into guide sleeve (press in onto stop)

Note:
^ The open side of seal faces toward thrust tube VW 454.