FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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02XA Transmission: Overview






Clutch Release Mechanism





1 Release bearing

Do not wash, only wipe off

Replace noisy bearings

Repairing release bearing with bonded plastic ring, refer to => [ Release Bearing, Checking or Servicing with Bonded Plastic Ring ] 02XA Transmission

Check release bearing with installed plastic ring, refer to => [ Checking Release Bearing with Stuck-On Plastic Ring ] 02XA Transmission

Replace if running marks are too deep, refer to => [ Checking Release Bearing with Stuck-On Plastic Ring ] 02XA Transmission

Allow retaining tabs of release bearing to engage in release lever

2 Torx(R) bolt, 35 Nm

Quantity: 3

Insert with Locking Fluid (AMV 185 101 A1)

3 Clutch release lever

Before installed, coat recess for slave cylinder plunger with Copper Paste (Z 381 351 TE)

4 Retaining spring

Secure to clutch release lever

5 Guide sleeve

Installation position: Oil drain hole points downward

Before pulling off/sliding on to protect sealing ring, pull heat-shrinkable tube over input shaft splines

6 Oil seal

For input shaft

Remove from the guide sleeve, refer to => [ (Item 5) Guide sleeve ] => [ Removing the Seal from the Guide Sleeve ] 02XA Transmission

Install into the guide sleeve, refer to => [ (Item 5) Guide sleeve ] => [ Installing the Seal all the way into the Guide
Sleeve ] 02XA Transmission

Fill half of volume between sealing lip and dust lip with Sealing Grease (G 052 128 A1)

7 O-Ring

Always replace

8 Plate spring

The camber on the inner diameter faces the guide sleeve => [ (Item 5) Guide sleeve ].

9 Intermediate piece

Installation position: install the anti-twist mechanism between the housing rib

10 Ball studs

Grease with MoS2 grease

11 Transmission

12 Clutch slave cylinder

Removing and installing, refer to => [ Clutch Slave Cylinder ] 02XA Transmission

Do not operate clutch pedal after removal

Observe work sequence when bleeding, refer to => [ Clutch System, Bleeding ] 02XA Transmission

Tighten bleeder valve to 4.5 Nm.

When inserting, push in so far until the bolt can be installed.

13 Internal hex bolt, 23 Nm

Self-locking

Replace

14 Bracket

For hose/line assembly

Fasten with clutch slave cylinder on transmission

15 Plunger

Coat end of plunger with Copper Grease (Z 381 351 TE )