Get Clutch -> 2 Clutch Release Mechanism, Servicing Guide for Volkswagen Golf 4 Door Fifth Generation (2003-2008)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

2

Clutch Release Mechanism, Servic‐

ing

⇒ “2.1 Line Assembly and Bleeder on the Clutch Slave Cylinder,

Removing and Installing”, page 52

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52

⇒ “2.3 Hose/Line Assembly or Pipe, Removing and Installing”,

page 53

⇒ “2.4 Input Shaft Seal, Replacing”, page 55

Special tools and workshop equipment required

♦ Torque Wrench 1331 5-50Nm - VAG1331-

1 - Transmission

2 - Input Shaft Seal

❑ Replacing. Refer to

⇒ “2.4 Input Shaft Seal,

Replacing”, page 55 .

3 - Clutch Slave Cylinder with

Release Bearing

❑ Must be replaced to‐

gether because they are

a single unit

❑ Do not wash the bear‐

ing, just wipe it off.

❑ Replace any loud bear‐

ings together with the

clutch slave cylinder

❑ Some clutch slave cylin‐

ders have a divided feed

line. Refer to

⇒ Fig. ““Clutch Slave

Cylinder -A- with Divi‐

ded Supply Line”“ , page

51

❑ Removing and instal‐

ling. Refer to

⇒ “2.2 Clutch Slave Cyl‐

inder with Release

Bearing, Removing and

Installing”, page 52 .

❑ Approximately from

05/2011: release bear‐

ing with an additional

plastic washer. Refer to

⇒ Fig. ““Approximately

from 05/2011: Release

Bearing with an Addi‐

tional Plastic Washer”“ ,

page 51 , pressure

plate is adapted

⇒ Fig. ““Only for Release Bearing with Additional Plastic Washer: Pressure Plate Diaphragm Spring

(-arrows-) with A Slightly Lower Installation Height.”“ , page 51

❑ Allocation. Refer to the Parts Catalog.

4 - Bolt

❑ Quantity: 3

❑ Replace after removing

50

Rep. Gr.30 - Clutch

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ Without locking compound 12 Nm (clutch slave cylinder with metal housing only)

❑ With locking fluid 15 Nm (for plastic clutch slave cylinders)

❑ carefully tighten diagonally in small stages so that clutch slave cylinder bolting eyelets do not break off

Note

Pay attention to the thread pitch on

the bolt when cleaning the threaded

hole in the clutch housing.

5 - O-Ring

❑ Install on the line connection

❑ Install with brake fluid

❑ Allocation. Refer to the Parts Catalog.

Clutch Slave Cylinder -A- with Divided Supply Line

The supply line is divided in area with -arrows- on some clutch

slave cylinders

Allocation. Refer to the Parts Catalog.

Approximately from 05/2011: Release Bearing with an Additional

Plastic Washer

Identified by: tabs -arrow- on the plastic washer.

Only for Release Bearing with Additional Plastic Washer: Pres‐

sure Plate Diaphragm Spring (-arrows-) with A Slightly Lower

Installation Height.

•

Only install the adapted release bearing and the adapted pres‐

sure plate together.

Allocation. Refer to the Parts Catalog.

2. Clutch Release Mechanism, Servicing

51

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

2.1

Line Assembly and Bleeder on the

Clutch Slave Cylinder, Removing and

Installing

Attaching and Removing the Hose/Line Assembly and the Pipe

to or from the Bleeder

– To remove, open the clip -2- with a screwdriver or a pointed

tool and pull off hose/line assembly or pipe -4- at the bleeder

-1-.

– To install, press hose/line assembly or pipe with the new O-

ring -3- into connection of bleeder, until clip audibly engages.

– Pull on the line to make sure it is secure.

Bleeder at Clutch Slave Cylinder, Removing and Installing

– To remove, open the clip -2- with a screwdriver or a pointed

tool and remove bleeder -4- from clutch slave cylinder -1-.

– To install, check the O-ring -3- on the clutch slave cylinder.

Press in bleeder at clutch slave cylinder connector until clip

engages audibly.

– To check, pull on the bleeder.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

2.2

Clutch Slave Cylinder with Release

Bearing, Removing and Installing

Note

The clutch slave cylinder and the release bearing are a single unit

and are replaced together.

Removing

•

Remove the transmission.

– Open the clip -2- with a screwdriver or a pointed tool and re‐

move bleeder -4- from clutch slave cylinder -1-.

52

Rep. Gr.30 - Clutch

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Remove the bolts -arrows-.

– Remove the clutch slave cylinder and the release bearing

-A-.

Installing

Install in reverse order of removal while. Note the following:

•

Tighten the slave cylinder bolts in small increments only.

Otherwise, there is the danger that the tabs with the fastening

holes could break off.

– Fasten the clutch slave cylinder with release bearing -item 4-

⇒ Item 4 (page 50) .

.

– Check the O-ring -3- on the clutch slave cylinder for damage.

– Install the bleeder -4- on the connection on the clutch slave

cylinder -1- until the clip -2- clicks into the place.

– To check, pull on the bleeder.

•

Install the transmission.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

2.3

Hose/Line Assembly or Pipe, Removing

and Installing

Special tools and workshop equipment required

♦ Hose Clamps - Up To 25 mm - 3094-

Removing

– Removed the complete air filter housing. Refer to ⇒ Rep. Gr.

23 ; Diesel Direct Injection System; Air Filter Housing, Re‐

moving and Installing or ⇒ Rep. Gr. 24 ; Air Filter; Air Filter

Housing, Removing and Installing .

Note

While performing the following work, make sure no brake fluid

comes into contact with the longitudinal member or the transmis‐

sion. If it does, clean the area thoroughly.

– Clamp the clutch master cylinder hose using a Hose Clamps

- Up To 25mm - 3094- .

Remove the hose/line assembly or pipe from the clutch master

cylinder as follows:

2. Clutch Release Mechanism, Servicing

53

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Open the circlip -3- with a screwdriver and remove the line

-1- and O-ring -2-.

Caution

Do not press the clutch pedal after removing the line.

Remove the hose/line assembly or pipe from the bleeder as fol‐

lows:

– Remove the circlip -2- with a screwdriver or a pointed tool and

remove the line -4- with O-ring -3- from the bleeder -1-.

Installing

Install in reverse order of removal while. Note the following:

– Install the hose/line assembly and pipe line -1- with the O-ring

-2- on the clutch master cylinder connection -4- until the clip

-3- audibly engages.

– Pull on the line to make sure it is secure.

54

Rep. Gr.30 - Clutch

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Press the line with O-ring -3- on the bleeder connection until

the secure clip engages.

– Pull on the line to make sure it is secure.

– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48 .

– Install the complete air filter housing. Refer to ⇒ Rep. Gr. 23 ;

Diesel Direct Injection System; Air Filter Housing, Removing

and Installing or ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing,

Removing and Installing .

2.4

Input Shaft Seal, Replacing

Special tools and workshop equipment required

♦ Puller - Crankshaft/Power Steering Seal - 1 - T20143/1-

♦ Seal Installer - Driveshaft - T40008-

♦ Sealing Grease - G 052 128 A1-

Procedure

•

Remove the transmission.

– Remove the clutch slave cylinder and the release bearing.

Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52 .

– Pry out input shaft seal using Puller - Crankshaft/Power Steer‐

ing Seal - 1 - T20143/1- .

Note

Be careful not to damage the contact surface for the seal on the

input shaft.

– Fill the space between the sealing and dust lip -arrow- halfway

with Sealing Grease - G 052 128 A1- .

– Lightly coat the outer circumference of the seal with transmis‐

sion fluid.

2. Clutch Release Mechanism, Servicing

55

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

– Drive in the seal using the Seal Installer - Driveshaft - T40008-

until it is flush.

– Install the clutch slave cylinder and the release bearing. Refer

to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52 .

•

Install the transmission.

56

Rep. Gr.30 - Clutch

Clutch -> 2 Clutch Release Mechanism, Servicing for Your Volkswagen Golf 4 Door Fifth Generation (2003-2008)

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