Clutch Release Mechanism, Servicing

Clutch release mechanism, servicing





Special tools and equipment
^ VW 454 Press piece
^ 30-100 Drift sleeve
^ VAG 1331 Torque wrench





1. Slave cylinder
2. Bolt
3. Bracket
4. Plunger
^ Coat end of plunger with copper grease
5. Release bearing
6. Bolt, 25 Nm Self-locking - Always replace
7. Leaf spring
8. Clutch release lever
9. Bolt, 15 Nm
10. Guide sleeve
11. Input shaft oil seal
12. Intermediate piece
13. Transmission





Fig. 1 Removing output shaft oil seal

- Pry oil seal out carefully with a screwdriver.





Fig. 2 Driving in output shaft oil seal

- Half fill between sealing and dust lips of new output shaft oil seal with grease G 052 128 A1.
- Tightly pull thin insulating hose over splines of output shaft.
- Press in output shaft oil seal.
Pressing depth: 3.5 mm
- Remove insulating hose.

Note: If the used output shaft is reused, repair pressing depth is 4.5 mm.





Fig. 3 Removing and installing clutch release lever
Removing

- Loosen bolt -1- and remove leaf spring -2-.
- Remove clutch release lever -4- together with release bearing -3- and intermediate piece -5-.
- Unhook retaining lugs of release bearing from release lever.

Installing
- Before installing clutch release lever, thinly coat contact surface of slave cylinder plunger with copper grease.
- Simultaneously set clutch release lever -4- and release bearing -3- on intermediate piece -5- as well as guide sleeve.
- Fit leaf spring -2- and tighten new bolt -1- to prescribed torque.





Fig. 4 Servicing release bearing

The three rectangular lugs (arrows) of the plastic ring engage in notches of the bearing race.