Service

Polo Estate 1998 ➤

5-speed manual gearbox 02J
Gearbox ID DSF DTA EKU EKV EKW EWY EWZ EXA

Edition 01.2000

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Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Polo Estate 1998 ➤
5-speed manual gearbox 02J

Repair Group
00 - Technical data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final drive, Differential rear

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Technical information should always be available to the foremen and mechanics, because their careful
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All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2011 Volkswagen AG, Wolfsburg 00056407520

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Code letters, gearbox allocation, ratios, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1 Transmission layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Calculating overall ratio "i" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1 Calculating overall ratio "i" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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30 - Clutch . . . . . . . . . . . .olk.s.wa.g.en. A.G. . . . . . .n.A.G .do.es. n.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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1 Servicing clutch ed control . . . . . . . . . . . . . . . . . . . . . r.a.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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1.1 Servicinguthclutch control . . . . . . . . . . . . . . . . . . . . . . . e. e.or. . . . . . . . . . . . . . . . . . . . . . . . . . .10
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1.2 Assembly
ss overview - Pedal cluster . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . .11

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1.3 Removing and installing over-centre spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

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1.4 Removing and installing clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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1.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

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1.6 Assembly overview - Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
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1.7 Removing and installing master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

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1.8 Bleeding clutch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

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2 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

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2.1 Servicing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3 Servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.1 rrectness of i
Servicing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
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34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

1 Servicing gear selector mechanism up to 09.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
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1.1 Servicing gear selector mechanism up to 09.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

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1.2 Installation position of gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

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1.3 Removing and installing gear selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

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1.4 Removing and installing gear stick housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

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1.5 Installing gear stick gaiter to gear stick knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

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1.6 Removing and installing gear stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

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1.7 Adjusting gear selector mechanism up to 09.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
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2 Servicing gear selector mechanism from 10.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
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2.1 Servicing gear selector mechanism from 10.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
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2.2 Installation position of gear selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
AG.

2.3 Removing and installing selector lever knob and gaiter . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
2.4 Servicing gear stick and gear stick housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
2.5 Assembly overview - Removing and installing selector cables . . . . . . . . . . . . . . . . . . . . . .65
2.6 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
2.7 Adjusting gear selector mechanism from 10.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
3 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
3.1 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
4 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
4.1 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
5.1 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
5.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
5.3 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5.4 Removing and installing cover for gearbox housing and 5th gear . . . . . . . . . . . . . . . . . . . .92

Contents i
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

5.5 Removing and installing gearbox housing and selector mechanism . . . . . . . . . . . . . . . . . .95
5.6 Removing and installing input shaft, output shaft (pinion shaft), differential and selector forks
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
5.7 Assembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
6 Servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
6.1 Servicing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
7 Dismantling and assembling gearbox selector mechanism up to 09.99 . . . . . . . . . . . . . . . .128
7.1 Dismantling and assembling gearbox selector mechanism up to 09.99 . . . . . . . . . . . . . . . .128
8 Dismantling and assembling gearbox selector mechanism from 10.99 . . . . . . . . . . . . . . . .133
8.1 Dismantling and assembling gearbox selector mechanism from 10.99 . . . . . . . . . . . . . . . .133
9 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
9.1 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
2 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
2.1 Adjusting input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
2.2 Table of adjustment shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
2.3 Performing measurement check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
3 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
3.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
3.2 From gearbox build date 04 09 0 the synchronisation for 1st gear has been modified . . . .191
4 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
4.1 Adjusting output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
5 Dismantling and assembling reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
5.1 Dismantling and assembling
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39 - Final drive, Differential
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1 Renewing
s au flanged shaft oil seals (gearbox installed) . . . .r a.c. . . . . . . . . . . . . . . . . . . . . . . . .203
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1.1 Renewing flanged shaft oil seals (gearbox installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
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2 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206

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2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206

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3 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220

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3.1 Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220

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4 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221

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4.1 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221

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ii Contents
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

00 - Technical data

1 - Gearbox identification
1.1 - Gearbox identification

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In the Caddy 1996 ▸, Polo Classic 1996 ▸and Polo Estate 1998 ▸ the 5-speed manual gearbox 02J is installed
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1.1 - Gearbox identification 1

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Manual gearbox 02J (arrow 2)

-> Code letters and date of manufacture of gearbox

Example: EKU 10 11 9
I I I I
I I I I
Code letters Day Month Year (1999) of
manufacture

Additional data depends on manufacture.

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The gearbox code letters are also shown onswthe
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1.2 - Code letters, gearbox
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Manual gearbox 5 speed 02J

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Manufactured from 01.99 01.99 10.99

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Allocation Model Caddy 1996 ▸ Polo Classic 1996 ▸ Polo Classic 1996 ▸
Polo Estate 1998 ▸ Polo Estate 1998 ▸
Engine 1.9 ltr. - 66 kW 1.9 ltr. - 66 kW 1.9 ltr. - 66 kW
rrectness of i

Turbo Diesel Turbo Diesel Turbo Diesel

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Ratio: Z2 : Z1 Final drive 60 : 19 = 3.158 60 : 19 = 3.158 60 : 19 = 3.158

1st gear 34 : 9 = 3.778 33 : 10 = 3.300 33 : 10 = 3.300
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2nd gear 36 : 17 = 2.118 35 : 18 = 1.944 35 : 18 = 1.944

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3rd gear 34 : 25 = 1.360 34 : 26 = 1.308 34 : 26 = 1.308

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4th gear 34 : 35 = 0.971 33 : 36 = 0.917 33 : 36 = 0.917

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5th gear 34 : 45 = 0.756 33 : 46 = 0.717 33 : 46 = 0.717

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Reverse gear 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600 17 : 10 x 36 : 20 = 3.060

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Speedometer drive 13 : 22 = 0.591 13 : 22 = 0.591 13 : 22 = 0.591
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Code letters DSF DTA EKU

2 00 - Technical data
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Capacity 2.0 litres 2.0 litres 2.0 litres

Specification Gear oil G50 SAE 75W90 (synthetic oil)
Clutch control hydraulic hydraulic hydraulic
Clutch plate ø 228 mm 228 mm 228 mm
Drive shaft flange ø 100 mm 100 mm 100 mm
Overall ratio in top gear 2.378 2.264 2.264

Manual gearbox 5 speed 02J

Code letters EKV EKW EWY
Manufactured from 10.99 10.99 09.00
to 09.00 09.00
Allocation Model Caddy
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Engine ed 1.9 ltr. - 66 kW 1.9 ltr.an-te66 kW 1.9 ltr. - 66 kW
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Ratio: Z2 : Z1 Final drives 60 : 19 = 3.158 60 : 19 = 3.158 60 : 19 = 3.158

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1st gear 34 : 9 = 3.778 34 : 9 = 3.778 34 : 9 = 3.778

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2nd gear 36 : 17 = 2.118 33 : 16 = 2.063 36 : 17 = 2.118
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3rd gear 34 : 25 = 1.360 31 : 23 = 1.348 34 : 25 = 1.360

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4th gear 34 : 35 = 0.971 29 : 30 = 0.967 34 : 35 = 0.971

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5th gear 34 : 45 = 0.756 29 : 39 = 0.744 34 : 45 = 0.756

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6th gear - - -

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Reverse gear 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600
Speedometer drive 13 : 22 = 0.591 13 : 22 = 0.591 13 : 22 = 0.591

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From 10.99 new selector mechanism. The selector cover of the gearbox has been modified
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From 09.00 modified synchronisation for the 1st gear and modified selector mechanism gearbox side
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Capacity 2.0 litres 2.0 litres 2.0 litres

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Specification Gear oil G50 SAE 75W90 (synthetic oil)

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Clutch control hydraulic hydraulic hydraulic

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Clutch plate ø 228 mm 228 mm 228 mm
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Drive shaft flange ø 100 mm 100 mm 100 mm
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Overall ratio in top gear Prote
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Manual gearbox 5 speed 02J

Code letters EWZ EXA
Manufactured from 09.00 09.00
to
Allocation Model Polo Classic 1996 ▸ Polo Classic 1996 ▸
Polo Estate 1998 ▸ Polo Estate 1998 ▸
Engine 1.9 ltr. - 81 kW 1.9 ltr. - 66 kW
Turbodiesel Turbodiesel
Ratio: Z2 : Z1 Final drive 60 : 19 = 3.158 60 : 19 = 3.158
1st gear 34 : 9 = 3.778 33 : 10 = 3.300
2nd gear 33 : 16 = 2.063 35 : 18 = 1.944
3rd gear 31 : 23 = 1.348 34 : 26 = 1.308

1.2 - Code letters, gearbox allocation, ratios, capacities 3

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Manual gearbox 5 speed 02J

4th gear 29 : 30 = 0.967 33 : 36 = 0.917
5th gear 29 : 39 = 0.744 33 : 46 = 0.717
6th gear - - -
Reverse gear 18 : 9 x 36 : 20 = 3.600 17 : 10 x 36 : 20 = 3.060
Speedometer drive 13 : 22 = 0.591 13 : 22 = 0.591

From 09.00 modified synchronisation for the 1st gear and modified selector mechanism gearbox side

Code letters EWZ EXA

Capacity 2.0 litres 2.0 litres
Specification Gear oil G50 SAE 75W90 (synthetic oil)
Clutch control hydraulic hydraulic
Clutch plate ø 228 mm 228 mm
Drive shaft flange ø 100 mm 100 mm
Overall ratio in top gear 2.349 2.264

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4 00 - Technical data
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

2 - Transmission layout
2.1 - Transmission layout

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Designation
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1 Engine yri
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2 Clutch Prote
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3 Gearbox
4 Input shaft
5 Output shaft/pinion shaft
6 Differential

Arrows point in direction of travel

2.1 - Transmission layout 5

 AG. Volkswagen AG d
Polo Estate 1998 ➤ ksw
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5-speed manual gearbox 02J - Edition 01.2000d by gu
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Gear ratios

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse gear
A - Final drive
T - Speedometer drive

Arrows point in direction of travel

6 00 - Technical data
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

3 - Calculating overall ratio "i"

3.1 - Calculating overall ratio "i"

Example:
5th gear Final drive
Drive gear ZG1
age=
n 34
AG. VolkswagZA1
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does
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Driven gear d by V ZG2 = 45
o
ZA2 = 60 ot gua
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i= Z2/ Z1 1) autho or
ac
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iG = Gear ratio = ZG2/ZG1 = 34 / 45 = 0.756

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iA = Axle ratio = ZA2 / ZA1 = 60 / 19 = 3.158
itte

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= iG x iA = 0.756 x 3.158 = 2.387

wit
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1) Z1 = No. of teeth driving gear, Z2 = No. of teeth driven gear
hole

spec
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4 - General repair instructions

rrectness of i
4.1 - General repair instructions
l purpos

To ensure perfect and successful gearbox repairs, the greatest care and cleanliness as well as the use of good
nform
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and proper tools is essential. Obviously, the basis rules for safety are also applicable during repair work.
m

at
om

A number of generally valid instructions applicable for the various repair procedures - which were previously
ion
c

repeated a number of times at numerous places in the Workshop Manual - are summarized here. They apply
in t
or

to this Workshop Manual.

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◆ When installing ensure that the dowel sleeves between the engine and gearbox are correctly located.
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◆ When changing a gearbox fill with gear oil to the lower edge of the filler hole.
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◆ Capacities and specifications => Page 2 .
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Notes:
Prote AG.

◆ If the oil level is topped up with the gearbox installed, carry out oil level check as follows:
◆ Fill with oil to the lower edge of the filler hole and refit filler plug. Start engine, engage a gear and allow
gearbox to turn for approx. 2 minutes. Switch off engine and again top-up oil to lower edge of filler hole.

Gaskets, sealing rings

◆ Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
◆ Apply sealant uniformly but not too thick.

3.1 - Calculating overall ratio "i" 7

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
◆ Renew "O-rings".
◆ Radial shaft oil seals.

Before installing:
-> Lightly oil outer circumference, fill space between sealing lips (arrow) with grease G 052 128 A1.
After installation:
Check gearbox oil; if necessary top-up to lower edge of oil filler hole, specification => Page 2 .

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Locking devices

h re
ole,

spec
◆ Renew circlips.
urposes, in part or in wh

◆ Do not overstretch circlips.

t to the co
◆ Circlips must locate properly in the groove.
◆ -> Renew spring pins
Installation position: Slot longitudinal to line of force.
rrectne

Bolts and nuts

ss o
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◆ Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
inform

◆ Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts
mer

and nuts in stages in a diagonal sequence.

atio
m

◆ Tightening torques as specified are for unoiled bolts and nuts.

o

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◆ Renew self-locking bolts and nuts.

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Bearings
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◆ Install needle bearings with lettered side (thicker metal) towards fitting tool.
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◆ Lubricate all gearbox bearings with gear oil. C py
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◆ Taper roller bearings fitted to one shaft must be renewed as a set. Use same make of bearings if possible!
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◆ Heat inner races to approx. 100 °C before installing.
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◆ Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.
Prote AG.

Shims
◆ Measure shims at several points with a micrometer. Tolerance variations make it possible to find the exact
shim thickness required.
◆ Check for burrs and damage.
◆ Only install perfect shims.

Synchronizer rings
◆ Do not interchange. When reusing always fit to the same gear.
◆ Check for wear and renew if necessary.
◆ Coat with gear oil before installing.

Selector gears
◆ Before installing clean and heat on a hot plate to approx. 100 °C.

8 00 - Technical data
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
◆ Temperature can be checked with temperature tester V.A.G 1558.

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4.1 - General repair instructions 9

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

30 - Clutch

1 - Servicing clutch control

1.1 - Servicing clutch control

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I - Assembly overview - pedal cluster

l purpos

=>page 11
III - Assembly overview - hydraulics
nf

=>page 21
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Notes:
o

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◆ Disconnect battery earth strap.

t

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◆ For vehicles with coded radio obtain radio code.

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◆ Lubricate all bearings and contact surfaces with poly resin grease part No. G 052 142 A2.
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10 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

1.2 - Assembly overview - Pedal cluster

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1 Mounting bracket
◆ Removing and installing
=> page 17
2 Hexagon bolt, 25 Nm
3 Self-locking hexagon nut, 25 Nm
◆ For mounting bracket to stud/brake servo
◆ Always renew
4 Self-locking hexagon nut, 25 Nm
◆ Always renew
5 Support
6 Mounting bush
◆ For mounting the column tube with steering column
7 Securing clip
◆ Removing and installing => Page 15

1.2 - Assembly overview - Pedal cluster 11

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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8 Pivot pin for clutch and brake pedal

itte

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◆ Installation position: The groove (arrow) is located on the clutch pedal side.
ab
ility
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9 Brake pedal
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10 Cap
h re
hole

11 Mounting bush
spec
es, in part or in w

◆ Check for wear, renew if necessary

t to the co

◆ Knock out with drift

◆ Press in by clamping in vice, use vice clamps
12 Cap
rrectness of i

13 Clutch pedal
l purpos

◆ Removing and installing => Page 15

14 Retainer
nf
ercia

◆ Removing and installing => Page 22

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12 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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15 Seal s
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◆ Always renew
an
d
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16 Master cylinder
erm

ab

◆ Removing and installing

ility
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=> page 25
wit
is n

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17 Socket head bolt, 20 Nm

ole,

spec

18 Supply hose
urposes, in part or in wh

t to the co

19 Securing clip
◆ Removing and installing => Page 15
20 Over-centre spring
rrectne

◆ Removing and installing

=>page 14
ss o
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1.2 - Assembly overview - Pedal cluster 13

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

1.3 - Removing and installing over-centre spring

Special tools and workshop equipment required

◆ 3317 Installation clamp

Removing

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- Take lower trims off lighting switch and steering column and remove driver's stowage compartment.
mer

atio
m

=> General body repairs, interior; Repair group 68; Stowage compartments, covers, trims Stowage compart‐
o

n
c

i
or

ments, covers, trims

thi
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sd
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o
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- Remove driver's footwell cover.

p

cum
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fo

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t.
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=> General body repairs, interior; Repair group 70; Removing and installing dash panel Removing and installing
Co
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- -> Tension over-centre spring -1- with clutch pedal and fit retaining clamp 3317 from above. Prote
cted AG.
agen

Note:

The drilling (arrow) faces towards clutch pedal.

- Bring clutch pedal to rest position, when doing this take out over-centre spring together with retaining clamp
3317 downwards.

14 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Installing

- Depress clutch pedal onto stop towards bulkhead.

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- -> First insert over-centre spring -1- into rear mounting (arrow A).
pt
an
d

- Now press front part of over-centre spring upwards until the retaining clamp seats on the mounting lug of
itte

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the clutch pedal (arrow B).

ab
pe

ility

- Take out retaining clamp whilst bringing clutch pedal to rest position.
ot

wit
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hole

spec

1.4 - Removing and installing clutch pedal

es, in part or in w

t to the co

Removing
rrectness of i
l purpos

- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With the ignition switched off disconnect the battery earth strap.
- Take lower trims off lighting switch and steering column and remove driver's stowage compartment.
nform
mercia

=> General body repairs, interior; Repair group 68; Stowage compartments, covers, trims Stowage compart‐
a
com

ti

ments, covers, trims

on in
r
te o

thi

- Remove driver's footwell cover.

s
iva

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cum
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=> General body repairs, interior; Repair group 70; Removing and installing dash panel Removing and installing
en
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dash panel
Co
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- Remove clutch pedal switch.
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- Removing over-centre spring => page 14 .
Prote
cted AG.
agen
- Separate clutch pedal from master cylinder => Page 25 .

1.3 - Removing and installing over-centre spring 15

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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nf
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o
- -> Remove clutch pedal securing clip from pivot pin by levering tab in direction of arrow -1-.

rm
m

- Then push securing clip -2- off pivot pin -1- in direction of arrow.

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- -> Remove brake pedal securing clip from pivot pin by levering tab up with a screwdriver -arrow 1- and
pushing clip off -arrow 2-.
- Pull clutch and brake pedal pivot pin out to the right, until the clutch pedal can be removed.

Installing

Installation is carried out in the reverse sequence, when doing this note the following:
- -> Align clutch pedal/brake pedal pivot pin so that the flats -A- are vertical.
- Fit clutch pedal onto pivot pin.
- Then install securing clip for clutch pedal.
- Fit securing clip -B- onto brake pedal end of pivot pin -arrow-.

16 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Engage clutch pedal with operating rod/master cylinder as follows:

- -> The retainer -A- must be fitted to the master cylinder operating rod -B-.
- To engage press clutch pedal towards bulkhead (direction of arrow). Ensure correctly located.
- Install and adjust new clutch pedal switch.

=> Running gear, ABS self-diagnosis; Repair group 01; Electrical check of ABS, ABS/EDL ITT Mark 20 GI and
ITT Mark 20 IE. Electrical check of ABS, ABS/EDL ITT Mark 20 GI and ITT Mark 20 IE.

1.5 - Removing and installing mounting bracket

Removing

- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With the ignition switched off disconnect the battery earth strap.
- Take lower trims off lighting switch and steering column and remove driver's stowage compartment.

=> General body repairs, interior; Repair group 68; Stowage compartments, covers, trims Stowage compart‐
ments, covers, trims G. Volkswage
nA n AG d
wage oes
olks not
- Remove driver's footwell dcover.
by
V gu
ara
e nte
o ris eo
h
=> General body repairs,
aut
interior; Repair group 70; Removing and installing
r a dash panel Removing and installing
c
dash panel ss
ce
le
un

pt
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d
itte

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erm

ab
ility
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is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f in

- Remove column tube with steering column.

form
mer

atio
m

=> Running gear, Axles, Steering; Repair group 48; Assembly overview: Steering column, column tube, steering
o

n
c

wheel and steering wheel with airbag; Removing and installing column tube with steering column Assembly
i
or

n thi

overview: Steering column, column tube, steering wheel and steering wheel with airbag Removing and installing
te

sd
va

column tube with steering column

i

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cum
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- Remove clutch pedal => Page 15 .

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1.4 - Removing and installing clutch pedal 17

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- -> Remove brake light switch -1- and brake pedal switch -2-.

- Separate brake pedal from brake servo.

=> Brake systems; Repair group 46; Brake pedal - assembly overview; Separating brake pedal from brake
servo Brake pedal - assembly overview Separating brake pedal from brake servo

- -> Unscrew relay carrier -1- from bulkhead and pull into footwell as far as possible.
- Push clutch and brake pedal mounting pin -2- in direction of arrow behind relay carrier until brake pedal
hangs loose.
- Remove brake pedal.

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- -> Unscrew strut -1- from mounting bracket and from bulkhead -arrows A-.
, is n

h re

- Unscrew nuts -arrows B- from brake servo and nut -arrow C- from bulkhead.
hole

spec
es, in part or in w

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rrectness of i
l purpos

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18 30 - Clutch
by lksw
cted agen
Prote AG.
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- -> Using a screwdriver, lever up cable channel -1- from mounting bracket -2-.

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- -> Pull connector -1- off in direction of arrow -A-.
- Unclip tab -2-.
- Pull out connector -3- for accelerator pedal position sender in direction of arrow -B- from cable channel -4-

rrectness of i
and place to rear.
- Pull brake servo into engine compartment as far as possible.
l purpos

- Turn mounting bracket 90° to the right and then pull to the left.
- Guide brake servo push rod out of mounting bracket.

nform
ercia

- Turn mounting bracket to first position again.

m

- Remove mounting bracket from passenger compartment.

at
om

ion
c

in t
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The accelerator pedal faces to driver's seat.

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Installing

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- Insert mounting bracket below instrument panel. ht. Cop py
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- Turn mounting bracket 90° to right and then pull to left.
- Guide brake servo push rod into mounting bracket.

- Turn mounting bracket to first position again.

- -> Guide connector -1- for accelerator pedal position sender from rear above cable channel -2- and insert
in direction of arrow -A-.
- Clip in tab -3-.
- Fit connector -4- in direction of arrow -B-.
- Clip on cable channel to top of mounting bracket.

- Press brake servo to bulkhead in installation position.

1.5 - Removing and installing mounting bracket 19

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

- -> Tighten nuts -arrows B- to brake servo and nut -arrow C- to bulkhead to 25 Nm.
- Tighten strut -1- on mounting bracket and bulkhead to 25 Nm -arrows A-.
- Insert brake pedal.

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- -> Insert bearing bush -A- for column tube/steering column mounting.
itte

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Installation position:
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The bearing bush lip -A- is on the clutch pedal side -1- and faces the driver's seat.

h re
ole,

spec
- Move clutch and brake pedal pivot pin to the right onto stop.
urposes, in part or in wh

- Tighten relay carrier to bulkhead.

t to the co
- Install clutch pedal => from Page 16 .

rrectness o
cial p

f inform
mer

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- -> Install and adjust brake light switch -1- and new brake pedal switch -2-.
by lksw
cted agen
Prote AG.

=> Running gear, ABS self-diagnosis; Repair group 01; Electrical check of ABS, ABS/EDL ITT Mark 20 GI and
ITT Mark 20 IE. Electrical check of ABS, ABS/EDL ITT Mark 20 GI and ITT Mark 20 IE.
- Install column tube with steering column.

=> Running gear, Axles, Steering; Repair group 48; Assembly overview: Steering column, column tube, steering
wheel and steering wheel with airbag; Removing and installing column tube and steering column Assembly

20 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
overview: Steering column, column tube, steering wheel and steering wheel with airbag Removing and installing
column tube and steering column AG. Volkswagen AG d
swagen oes
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Vol
- Install driver's footwell
ed b cover.
y gu
ara
ris nte
tho eo
=> General bodys arepairs, interior; Repair group 70; Removing and installing
u ra
c dash panel Removing and installing
dash panel s

ce
e
nl

pt
- Install driver's stowage compartment.
du

an
itte

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erm

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=> General body repairs, interior; Repair group 68; Stowage compartments, covers, trims Stowage compart‐

ility
ot p

ments, covers, trims

wit
, is n

h re
hole

spec
es, in part or in w

1.6 - Assembly overview - Hydraulic system

t to the co
rrectness of i
l purpos

nform
mercia

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1 Brake fluid reservoir

2 Supply hose
3 Master cylinder
◆ Removing and installing
=> page 25
4 Seal
◆ Always renew

1.5 - Removing and installing mounting bracket 21

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

5 Retainer
◆ Replace only with master cylinder removed
◆ Removing =>Fig. 1
◆ Pressing on =>Fig. 2
6 Clutch pedal
◆ Removing and installing => Page 15

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tion in
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7 Seal
do
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◆ Pull onto pipe/hose connection

fo

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◆ Insert with brake fluid

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8 Pipe/hose assembly
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◆ Allocate using parts catalogue
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9 Bracket
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◆ Secured to body
10 Dust cap
11 Bleed valve
◆ Bleeding clutch system
=> page 27
12 Slave cylinder
◆ Remove the following components before removing slave cylinder:
◆ For selector mechanism up to 09.99
- Gear selector cable from gear selector lever =>Page 39
- Relay lever and actuating arm for gate selector cable => Page 41

22 30 - Clutch
 n AG. Volkswagen AG do
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ran
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ut or
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◆ After installing adjust gear selector mechanism =>Page 52 c
ss

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urposes, in part or in wh

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cial p

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mer

atio
om

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c

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◆ For selector mechanism from 10.99

- Gear selector cable from gear selector lever =>Page 65
- Relay lever => Page 66
◆ After installing adjust gear selector mechanism =>Page 70

13 Collared securing bolt, 25 Nm

14 Gearbox
15 Clip
16 Seal
◆ Pull onto pipe/hose connection
◆ Insert with brake fluid
17 Support bracket

1.6 - Assembly overview - Hydraulic system 23

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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urposes, in part or in wh

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18 Hose bracket

ss
◆ Secure to control cable/gear selector cable support bracket

o
cial p

f in
19 Hexagon socket head bolt,

form
25 Nm
mer

atio
20 Clip
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24 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.1 Lever retainer -A- off in direction of arrow

-> Fig.2 Press master cylinder operating rod in retainer -A- in direction of arrow

1.7 - Removing and installing master cylinder

Special tools and workshop equipment required

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◆ T10005 Pliers

t to the co
Removing

rrectness of i
- Remove coolant expansion tank and lay to one side.
l purpos

Note:
Do not open cooling system.
nf
ercia

- Remove air cleaner if fitted left in engine compartment

rm
m

atio
om

=> Repair group 24; Servicing injection system Servicing injection system
n in
or c

thi

- Place lint-free cloth under the control unit and hydraulic unit.
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1.6 - Assembly overview - Hydraulic system 25

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- -> Pull off return pipe/hose hose -A- to brake fluid reservoir and seal.
- Lever clip -B- for pipe/hose assembly out from master cylinder with a screwdriver -1-.
- Pull pipe/hose assembly -C- out from master cylinder and seal.
- Remove bolts -D-.
- Take lower trims off lighting switch and steering column and remove driver's stowage compartment.
olksw
=> General body repairs, interior; Repair group 68; Stowage agecompartments,
n AG. V covers,
agen AG
does trims Stowage compart‐
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ments, covers, trims by Vol not
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spec
urposes, in part or in wh

t to the co
rrectne
- Remove driver's footwell cover.

ss
=> General body repairs, interior; Repair group 70; Removing and installing dash panel Removing and installing

o
cial p

f i
dash panel

nform
mer

atio
-> Separate master cylinder operating rod from clutch pedal as follows:
om

n
c

i
or

n thi
- Carefully pull clutch pedal towards passenger compartment.
te

sd
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- Press both sides of mounting inwards using pliers T10005 (arrows).

iv

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pr

c
- Pull piston rod with mounting out of pedal forwards.

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- Take out master cylinder from engine compartment.

Installing

Installation is carried out in the reverse sequence, when doing this note the following:

- -> The retainer -A- must be fitted to the master cylinder operating rod -B-.
- To engage press clutch pedal towards bulkhead (direction of arrow). Ensure correctly located.
- Bleeding clutch system after installing master cylinder=>page 27 .

26 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

1.8 - Bleeding clutch system

Special tools and workshop equipment required

◆ V.A.G. 1869 Brake filling and bleeding unit

- Brake fluid specifications.

=> Brake systems; repair group 47 Booklet, Bleeding brake system, vehicles with or without ABS

- To bleed system use bleed hose V.A.G 1238/B 3 - 670 mm long, if necessary.

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- Connect bleed hose to brake bleeding appliance collector bottle.

es, in part or in w

t to the co

- -> Connect bleed hose -A- to slave cylinder and open bleed valve.
- Depress clutch pedal several times after completion of bleeding process.
rrectness of i
l purpos

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mercia

a
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tion in
r
te o

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1.8 - Bleeding clutch system 27

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

2 - Servicing clutch release mechanism

2.1 - Servicing clutch release mechanism

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1 Gearbox
es, in part or in w

t to the co

2 Ball stud, 25 Nm
◆ Lubricate with MoS2 grease
3 Input shaft oil seal
rrectness of i

◆ Renewing => Page 122

l purpos

4 Guide sleeve
◆ With vulcanised O-ring
nform
ercia

◆ If damaged replace guide sleeve and O-ring together

◆ Lubricate guide sleeve in area of release bearing with MoS2 grease
m

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om

5 Retaining spring
ion
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◆ Secure to clutch release lever

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28 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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6 Securing bolt, 20 Nm rise
d
nte
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7 Clutch release lever auth
ra
s c
8 Release bearing s
ce
le
un

pt

◆ Do not wash-out bearing, only wipe

an
d
itte

◆ Renew noisy bearings

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erm

ab

◆ Lubricate surfaces which contact release lever with MoS2 grease

ility
ot p

9 Securing bolt, 20 Nm
wit
is n

10 Slave cylinder
h re
ole,

spec

◆ Removing and installing

urposes, in part or in wh

=> Page 22
t to the co

11 Plunger
◆ Grease end of plunger with MoS2 grease
rrectness o
cial p

f inform
mer

atio
om

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29
cop Vo
by lksw
Prote
cted 2.1 - Servicing clutch release mechanism
AG.
agen
 AG. Volkswagen AG d
agen oes
olksw not
y V gu
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Polo Estate 1998 ➤ thor eo
u ra
5-speed manual gearbox
ss a 02J - Edition 01.2000 c

ce
e
nl

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du

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itte

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ility
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es, in part or in w

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mercia

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12 Assembly bolt
◆ Secures the clutch release lever when installing gearbox
◆ Unscrew after gearbox has been installed

Note:

If the assembly bolt (Item 12 ) is not available, an M 8 x 35 bolt can be used.

30 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

3 - Servicing clutch
3.1 - Servicing clutch

AG. Volkswagen AG d
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rise nte
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pt
du

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itte

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ility
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es, in part or in w

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Special tools and workshop equipment required

◆ 3067 Counter-hold
◆ 3190 A Centralizing mandrel
◆ V.A.G 1331 Torque wrench

3.1 - Servicing clutch 31

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
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nl

pt
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an
itte

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erm

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ility
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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
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ion
c

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for

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Notes:
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◆ Before replacing the clutch and pressure plate note fault finding transmission No.9 - Defects on the clutch
by lksw
cted agen
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and clutch mechanism
AG.

◆ Replace clutch plates and pressure plates with damaged or loose rivets
◆ Select correct clutch plate and pressure plate according to parts list and engine code.

1 Flywheel
◆ Ensure centring pins are a tight fit
◆ Contact surface for clutch lining must be free of grooves, oil and grease
◆ Removing and installing

=> Repair group13; Removing and installing sealing flange and flywheel/drive plate

32 30 - Clutch
 Polo Estate 1998 ➤
5-speed
olksw
manual gearbox 02J - Edition 01.2000
AG. V agen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
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ility
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wit
is n

h re
ole,

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urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

en
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2 Clutch plate
◆ Diameter
=>from page 2
◆ Installation position: spring cage faces the pressure plate
◆ Centring => Fig. 1
◆ Lightly grease splines

Note:

Clean input shaft splines and on used clutch plates, the hub splines, remove corrosion and apply only a very
thin coating of grease Part No: G 000 100 to the input shaft splines. Then move clutch plate to and fro on input
shaft until hub moves freely on shaft. Excess grease must be removed.

3.1 - Servicing clutch 33

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
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ility
3 Pressure plate
ot

wit
, is n

◆ Removing and installing => Fig. 1

h re
hole

◆ Check ends of diaphragm spring

spec

=> Fig. 2
es, in part or in w

t to the co

Note:
rrectness of i

Pressure plates are protected against corrosion and greased. Only the contact surface may be cleaned, oth‐
erwise the service life of the clutch will be considerably reduced.
l purpos

4 Bolt
nform
ercia

◆ Allocate using parts catalogue

• 20 Nm
m

a
com

◆ Loosen and tighten gradually and diagonally

tion in
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te o

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34 30 - Clutch
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.1 Centring clutch plate and removing and installing pressure plate

- Loosen and tighten bolts gradually and diagonally.

- Reverse position of retainer 3067 when removing.

Note:

Pressure plate contact surface and clutch plate must make full contact with flywheel. Tighten bolts diagonally
and evenly to prevent damage to nthe centring holes in the pressure plate housing and the centring pins in the
AG. Volkswagen AG d
flywheel. olkswage oes
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ility
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es, in part or in w

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rrectness of i
l purpos

nform
mercia

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tion in
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-> Fig.2 Checking ends of the diaphragm spring
Prote AG.

• Wear up to half the thickness of the diaphragm spring is permitted.

3.1 - Servicing clutch 35

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

34 - Controls, Housing

AG. Volkswagen AG d
agen oes
1 - Servicing gear selector mechanism up to 09.99 d by Volksw not
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1.1 - Servicing gear sselector
sa
ut
mechanism up to 09.99 ra
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nl

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erm

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ility
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mercia

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ion
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for

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1.2 - Installation position of gear selector mechanism

A - Gear change cable
B - Gate selector cable
C - Heat shield
◆ Remove before removing the gear selector mechanism.

Arrow -A- Gear selection movement

36 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Arrow -B- Gate selection movement

1 Gear selector lever

2 Relay lever with actuating arm/gate selector cable

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I - Removing and installing gear selector control cables => Page 39

rrectness of i

II - Removing and installing gear stick housing => Page 59

III - Removing and installing gear lever => Page 48
l purpos

Adjusting gear selector mechanism up to 09.99 => Page 52

nform
mercia

- Before removing the gear selector mechanism, separate exhaust system behind catalyst
at
om

ion
c

in t
r

Notes:
o

his
ate

do
riv

◆ Before working on the selector mechanism, disconnect earth strap from the battery in the engine compart‐
p

cum
for

ment.
en
ng

t.
yi
◆ Note radio code on vehicles with coded radio.
Co
op py
◆ To replace the selector cables remove gear selector mechanism complete.
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◆ Do not kink selector cables. p by
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1.2 - Installation position of gear selector mechanism 37

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
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h
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Special tools and workshop equipment
ss a
required c

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nl

pt
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◆ V.A.G 1331 Torque wrench

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itte

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ility
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1.3 - Removing and installing gear selector cables

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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38 34 - Controls, Housing
 AG. Volkswagen AG d
agen oes
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rise nte
tho e o Polo
Estate 1998 ➤
au ra
ss 5-speed manual gearbox 02J - Edition 01.2000
c

ce
e
nl

pt
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an
Note:

itte

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ab
Lubricate all mountings and sliding surfaces with Polyurea grease Part No. G 052 142 A2.

ility
ot p

wit
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1 Gear selector cable

h re
◆ Installation position => Page 36
hole

spec
2 Gate selector cable
es, in part or in w

t to the co
◆ Pull off actuating arm (item 18 ) by pulling lug in direction of arrow
◆ Installation position => Page 36
◆ Install before installing gear selector cable

rrectness of i
3 Circlip
l purpos

◆ When removing do not damage bellows

nform
mercia

at
om

ion
c

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or

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for

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Prote AG.

4 Hexagon combi bolt,

25 Nm
◆ With shoulder
◆ Gear selector cable to gear change lever
5 Rubber bush
◆ For gear change cable to gear selector lever
◆ To renew bellows press out of end piece
6 Washer
◆ Install between gear selector cable and gear selector lever

1.3 - Removing and installing gear selector cables 39

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

7 Gear selector lever

◆ Only fits in one position
◆ After installing adjust gear selector mechanism => Page 52
◆ Installation position => Page 43

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ility
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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

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priv

cum
for

en
ng

t.
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Cop py
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Prote AG.

8 Square nut
◆ Insert into gear selector lever
9 Self-locking hexagon nut, 25 Nm
◆ For gear selector lever
10 Bellows
◆ Carefully pull over gear selector cable end piece
◆ Use MoS2 grease
11 Hexagon bolt, 25 Nm
◆ For support bracket
12 Support bracket
13 Distance piece
14 Bush
◆ Support bracket mounting to gearbox

40 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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un

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pe

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ot

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hole

spec
es, in part or in w

15 Bellows
t to the co

◆ Carefully pull over gear selector cable end piece

◆ Use MoS2 grease
rrectness of i

16 Relay lever
◆ Remove before removing clutch control
l purpos

◆ Installation position => Page 43

◆ Servicing => Page 131
nform
ercia

17 Self-locking hexagon nut, 15 Nm

m

◆ For relay lever to actuating arm

a
com

ti

◆ Only loosen to adjust selector mechanism

on in
r

18 Actuating arm
te o

thi
s
iva

◆ With pivot pin to mount relay lever

do
r
rp

◆ Installation position => Page 43

um
fo

en

◆ Servicing => Page 131

ng

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cted agen
Prote AG.

1.3 - Removing and installing gear selector cables 41

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
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pt

19 Rubber bush
du

an
itte

y li

◆ For gate selector cable to actuating arm

erm

ab

◆ Press in and out with drift

ility
ot p

20 Self-locking hexagon nut, 30 Nm

wit
, is n

h re

◆ For balance weight

hole

spec

21 Balance weight
es, in part or in w

t to the co

◆ Remove to adjust selector mechanism

22 Self-locking hexagon nut, 15 Nm
◆ For selector cable to selector housing
rrectness of i

23 Rubber washer
l purpos

24 Rubber bush
◆ For gear selector cable/gear change lever
nform

◆ Press in and out with drift

ercia

25 Rubber bush
m

at
om

◆ For gate selector cable/selector bracket

on
c

◆ Press in and out with a drift

in t
or

his
ate

do
priv

cum
for

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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

42 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ho eo
aut ra
ss c

ce
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un

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an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

-> Installation position gear selector lever/relay lever actuating arm/balance weight

spec
urposes, in part or in wh

t to the co
1 - Gear selector lever
2 - Relay lever
Locates in guide rail of gear shift lever (arrow -A-)

rrectne
Lubricate with MoS2 grease
3 - Actuating arm
Flats (arrow -B-) of axis face mounting, relay lever only fits in one position
ss
4 - Balance weight
o
cial p

f i

Bolt on to gear selector lever

nform
mer

atio

Note:
om

n
c

i
or

For ease of illustration the linkage and switch for reverse light have been removed.
thi
te

sd
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fo

en
ng

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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

1.3 - Removing and installing gear selector cables 43

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

1.4 - Removing and installing gear stick housing

AG. Volkswagen AG d
agen oes
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or eo
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nl

pt
du

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itte

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erm

ab
ility
ot p

1 Selector lever knob

wit
, is n

2 Sleeve
h re
hole

spec

3 Rubber cover
es, in part or in w

◆ Connect to gear stick knob before installing =>Page 47

t to the co

4 Leatherette gaiter
◆ Pull off from frame
rrectness of i

◆ Connect to gear stick knob before installing =>Page 47

5 Frame
l purpos

◆ Pull off centre console upwards

6 Boot
nf
ercia

◆ Not fitted to all vehicles

rm
m

atio

◆ Pull off frame to remove

om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

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f

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t.
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Cop py
t. rig
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Vo
o
by c lksw
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Prote AG.

44 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

7 Plastic nut
ion in

◆ Console to gear stick housing

r
te o

thi

◆ Remove before removing gear selector mechanism

s
iva

do
r

8 Spacer sleeve
rp

cum
fo

◆ Between console and gear stick housing

en
ng

t.
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op
9 Gasket C py
ht. rig
◆ Between selector housing and floor
rig ht
py by
o Vo
◆ Self-adhesive by c lksw
cted agen
◆ Bond to gear stick housing Prote AG.

10 Hexagon bolt, 15 Nm
◆ For mounting plate to gear stick housing
11 Selector housing

1.4 - Removing and installing gear stick housing 45

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum

12 Gasket
fo

en
ng

t.
◆ Self-adhesive
yi Co
op
◆ Bond underneath gear stick housing
C py
t. rig
gh ht
yri
13 Gasket p by
o Vo
by c lksw
◆ Between selector cables and gear stick housing cted agen
Prote AG.
14 Central console

46 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

1.5 - Installing gear stick gaiter to gear stick knob

n AG. Volkswagen AG do
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ir se tee
tho
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a ac
ss

ce
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un

pt
an
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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
◆ Rubber boot

rrectness of i
- Engage with gear stick knob
l purpos

◆ Leatherette gaiter

nform
ercia

- Turn cover inside out.

- -> Insert gear stick knob in gaiter (arrow).
m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

- -> Secure gaiter on gear stick knob with sleeve (arrow).

- Install gear stick knob and gaiter together.

1.5 - Installing gear stick gaiter to gear stick knob 47

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

1.6 - Removing and installing gear stick

n AG. Volkswagen AG do
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Note:
nform
ercia

Lubricate all mountings and sliding surfaces with Polyurea grease Part No. G 052 142 A2.
m

a
com

1 Hexagon bolt, 25 Nm
ion in
r

◆ For gear stick housing to body

te o

thi
s
iva

2 Hexagon bolt, 25 Nm
do
r
rp

◆ For gear stick housing to body

um
fo

en
ng

3 Cover plate
t.
yi Co
op py
4 Gate selector cable t. C rig
gh ht
yri by
◆ On gate selector bracket cop Vo
by lksw
cted
5 Gear selector cable
agen
Prote AG.
◆ On gear lever
6 Spring clip
7 Hexagon bolt, 15 Nm
◆ For fulcrum pin to mounting plate
8 Fulcrum pin

48 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
9 Mounting plate Prote AG.

10 Lock washer
◆ Removing => Fig. 3
11 Bush
◆ Only fits in one position
12 Gate selector bracket
13 Gate selector housing
◆ Fit into mounting plate after fitting the complete gear stick
14 Cap
◆ Fitting => Fig. 1
15 Bush
16 Spring
17 Guide bush
◆ Locate on bush (item 15)
18 Bush

1.6 - Removing and installing gear stick 49

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

19 Circlip
spec

◆ Removing and installing

es, in part or in w

t to the co

=>Fig. 2
20 Spacer sleeve
21 Spring
rrectness of i

22 Gear stick guide

l purpos

23 Gearbox selector lever

24 Damping washer
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
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Vo
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by c lksw
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Prote AG.

50 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.1 Fitting cap

- Press on from side (arrow 1).

- Press opening together to form a slot.
AG. Volkswagen AG d
Note: lksw
agen oes
not
Vo gu
d by ara
If necessary heat cap (e.g. hot water). orise nte
eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

-> Fig.2 Removing and installing circlip nform

ercia

- To remove and install the circlip pull gear stick in arrow direction -A- and at the same time push down spacer
m

at
om

bush onto stop with a screwdriver in arrow direction -B-.

ion
c

in t
or

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ate

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for

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Prote AG.

-> Fig.3 Removing lock plate for gate selector bracket and gear stick guide/gate selector housing

- Lift tab in direction of arrow.

1.6 - Removing and installing gear stick 51

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

1.7 - Adjusting gear selector mechanism up to 09.99

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Special tools and
ss a workshop equipment required
u ra
c

ce
le
un

pt
◆ 3192 Gear lever gauge

an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

◆ 3192/1 Wedge
a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Special tools and workshop equipment required

◆ V.A.G 1331 Torque wrench

Notes:

The following are prerequisites for correct gear linkage adjustment:

◆ Perfect gear linkage operating and transfer elements.

◆ Mounting of gear and gate selector cables to all operating elements OK (not worn).
◆ Gear and gate selector cables move smoothly.

52 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Gearbox, clutch and clutch release mechanism must also be in good condition.

Gearbox in neutral.

- Remove gear stick knob and gaiter => Page 59

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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ce
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un

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d
itte

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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

- Remove balance weight => Page 42 .

rrectness of i

- -> Loosen bolt -A- and nut -B-, until the gear selector cable and actuating arm/gate selector cable are free
l purpos

to move in the elongated holes.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- -> Loosen bolt -C-, pull off foam seal in area of bolt -C- if necessary.
- Insert gear stick jig.
- Swing jig securing hook under mounting plate and tighten nut -D-.
- Press gear stick into left-hand detent of sliding piece.
- Press gear stick together with sliding piece to left onto stop (direction of arrow) and tighten sliding piece with
bolt -E-.

1.7 - Adjusting gear selector mechanism up to 09.99 53

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

- -> Press gear stick into the right-hand detent (direction of arrow).
- Tighten bolt -C-.

- Insert wedge and pin.

- -> Slide wedge between gear selector lever and selector cover plate, ensuring no play.

Note: n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
d ran
Wedge must not liftorgear stick.
ise
tee
th or
au ac
- ss
In this position secure gear selector cable and actuating arm/gate selector cable, when doing this, check
ce
le

position of wedge.
un

pt
an
d

- Remove gear stick jig.

itte

y li

- Fit gear stick knob and gaiter =>Page 59 .

rm

ab
pe

ility
ot

Functional check
wit
, is n

h re
hole

spec

• The gearstick must rest in the 3rd/4th gear plane with gearbox in neutral.
es, in part or in w

t to the co

- Operate clutch.
- Select all gears several times. Pay particular attention to the operation of the reverse gear lock.
rrectness of i

Should a gear fail to engage smoothly after repeated selection, the selector shaft play (lift) should be checked
as follows:
l purpos

- Engage 1st gear.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

54 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
- Press gear thostick
r to left onto stop and release. eo
- At the same
s au time observe selector shaft in gear box (2ndr mechanic). ac
- -> When moving the gear stick the selector shaft must move approx. 1 mm (in direction of arrow).
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

- -> Should this not be the case, disengage first gear and again loosen nut -A- for the actuating arm/gate
orm

selector cable mounting. (The gate selector cable has a certain amount of play at the mounting - due to the
m

atio
m

transfer elements).
o

n in
c

- Take up gate selector cable play, by lightly pressing the mounting towards the bulkhead (direction of arrow).
or

thi
e

- Tighten nut -A- in this position.

t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.

1.7 - Adjusting gear selector mechanism up to 09.99 55

 Polo Estate 1998 ➤
5-speed manual gearbox 02J -enEdition
AG. Volksw01.2000
agen AG
wag doe
ks s no
Vol
2 - Servicing gear selector by mechanism from 10.99
gu t
ara
ed nte
ris
tho eo
au ra
2.1 - Servicing gear selector
ss mechanism from 10.99 c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.2 - Installation position of gear selector mechanism

A - Gear change cable
B - Gate selector cable
C - Heat shield
◆ Remove before removing the gear selector mechanism.

Arrow -A- Gear selection movement

Arrow -B- Gate selection movement

1 Gear selector lever

2 Relay lever

56 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
I - Removing and installing gearstick knob and gaiter => Page 59
es, in part or in w

t to the co
II - Servicing gear stick and gear stick housing => Page 61
III - Assembly overview: Removing and installing operating cables => Page 65

rrectness of i
Removing and installing selector mechanism => Page 68
l purpos

Adjusting gear selector mechanism from 10.99 => Page 70 nform

ercia

Notes:
m

a
com

tio

◆ Before working on the selector mechanism, disconnect earth strap from the battery in the engine compart‐
n in
r

ment.
te o

thi
s

◆ Note radio code on vehicles with coded radio.

iva

do
r

◆ To replace the selector cables remove gear selector mechanism complete.

rp

cum
fo

◆ Do not kink selector cables.

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.2 - Installation position of gear selector mechanism 57

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Special tools and workshop equipment required

rrectne
◆ V.A.G 1331 Torque wrench

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

◆ V.A.G 1275 Pliers

58 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

2.3 - Removing and installing selector lever knob and gaiter

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1 Selector lever knob

◆ Screw on and off together with gaiter
2 Cover
◆ Separating from gear stick knob => Fig. 1
◆ Connect to gear stick knob before installing Fig. 1
◆ Remove and install together with gear stick knob
3 Sleeve
4 Clamp
◆ To secure gear stick knob on gear stick
5 Frame

2.3 - Removing and installing selector lever knob and gaiter 59

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.1 Separating cover from gear stick knob and assembling to gear stick knob

- Turn cover inside out.

- Carefully lever clamping sleeve (arrow) off with a screwdriver and pull the gear stick knob out.

Installation is carried out in the reverse sequence, when doing this note the following:

- Insert gear stick knob in cover.

- Push clamping sleeve onto gear stick knob and engage.
- Install gear stick knob and gaiter together.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

60 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

2.4 - Servicing gear stick and gear stick housing

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform

Note:
mer

atio
m

Lubricate all mountings and sliding surfaces with Polyurea grease Part No. G 052 142 A2.
o

n
c

i
or

n thi
te

1 Circlip
sd
iva

o
pr

◆ Removing and installing

um
r
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=>Fig. 1
en
ng

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op
2 Bush C py
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3 Spring
rig ht
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4 Bush
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Prote AG.
5 Torx screw, 5 Nm
6 Cover plate
7 Damper
8 Bearing shell
9 Gear stick guide

2.4 - Servicing gear stick and gear stick housing 61

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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d
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erm

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ility
ot p

wit
is n

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

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or

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te

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pr

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fo

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Prote AG.

10 Damping washer
11 Gasket
◆ Between selector housing and floor
◆ Self-adhesive
◆ Bond to gear stick housing
12 Gearbox selector lever
13 Plastic nut
◆ For console on gear stick housing
14 Damper
15 Selector housing
16 Bush
17 Bolt, 25 Nm
18 Fulcrum pin
19 Guide bush
20 Spring
◆ Installing => Fig. 2

62 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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es, in part or in w

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21 Gate selector bracket

22 Torx screw, 5 Nm
23 Base plate
rrectness of i

◆ Open tabs to remove

l purpos

◆ Renew
24 Lock washer
nf
ercia

25 Gate selector cable

orm

◆ On gate selector bracket

m

atio
m

◆ Installation position => Page 56

o

n in
c

26 Gear selector cable

or

thi
te

sd

◆ Press onto gear stick guide

iva

o
r

◆ Installation position => Page 56

rp

cu
o

m
f

en
ng

27 Bush yi
t.
Co
op
◆ Only fits in one position C py
t. rig
gh ht
28 Lock washer yri
p by
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by c lksw
cted agen
Prote AG.

2.4 - Servicing gear stick and gear stick housing 63

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.1 Removing and installing circlip

- To remove and install the circlip pull gear stick in arrow direction -A- and at the same time push down spacer
bush onto stop with a screwdriver in arrow direction -B-.

AG. Volkswagen AG d
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spec
urposes, in part or in wh

-> Fig.2 Installing spring t to the co

- Insert spring so that the spring extension -A- lies above pin (arrow).
- Then pull spring extension -B- down so that it reaches below pin (arrow).
rrectness o
cial p

f inform
mer

atio
om

n
c

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Cop py
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Vo
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Prote AG.

64 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

2.5 - Assembly overview - Removing and installing selector

en AG. V
olkcables
swagen AG
wag does
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rrectness of i
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nform
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a
com

tion in
r
te o

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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.

Note:

Lubricate all mountings and sliding surfaces with Polyurea grease Part No. G 052 142 A2.

1 Gear selector cable

◆ Press onto gear stick guide
◆ Installation position => Page 56
2 Gate selector cable
◆ On gate selector bracket
◆ Installation position => Page 56
3 Circlip
4 Circlip
◆ Do not damage cable when removing
5 Selector housing

2.5 - Assembly overview - Removing and installing selector cables 65

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
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urposes, in part or in wh

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6 Support bracket
7 Bush
rrectne

◆ Support bracket mounting to gearbox

8 Distance piece
ss o
cial p

9 Hexagon bolt, 25 Nm
f inform

◆ For support bracket

mer

10 Cable locking mechanism

atio
om

◆ For gate selector cable to relay lever

c

i
or

n thi
e

11 Cable locking mechanism

t

sd
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◆ For gear selector cable to gear change lever

pr

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12 Circlip
en
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13 Bush Cop py
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14 Relay lever
gh ht
pyri by
Vo
o
◆ Installation position => Page 68
c by lksw
cted agen
Prote AG.

66 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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un

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ility
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wit
is n

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

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te

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pr

cum
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fo

en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

15 Shoe
16 Gearbox selector lever
◆ With balance weight
◆ Install so that the master spline aligns with selector shaft
◆ After installing adjust gear selector mechanism => Page 70
◆ Installation position => Page 68
17 Hexagon nut, 25 Nm

2.5 - Assembly overview - Removing and installing selector cables 67

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Installation position of gearbox selector lever/relay lever

1 - Gear selector lever
With balance weight
2 - Relay lever agen
AG. Volkswagen AG d
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Locates in guide rail of gear selectorVolever
lksw via shoe (arrow) not
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2.6 - Removing and installing selector mechanism s

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ercia

Removing
m

at

- -> Lever gate selector cable -A- and gear selector cable -B- off gearbox using an open jaw spanner.
om

ion
c

in t
or

1 = 13 mm open jaw spanner, commercially available

his
ate

do
priv

cum
for

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t.
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Cop py
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Prote AG.

68 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- -> Unclip hose -A- from cable support bracket.
- Remove cable support bracket from gearbox (arrows).

AG. Volkswagen AG d
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pt
du

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ility
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- Pull the gear stick cover off the centre console.

h re
hole

- -> Destroy clip (arrow) and pull gear stick knob off with cover.

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

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n in
or c

thi
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sd
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cu
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- -> Remove nuts -arrows- for console.

f

en
ng

t.
yi
- Remove cross supports below the exhaust system.
Co
op py
- Separate exhaust system after front exhaust pipe at double clamp.
t. C rig
gh ht
pyri by
Vo
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by
=> Repair group 26; Removing and installing parts of exhaust system. Removing and installing parts of exhaust
Prote
cted AG.
agen
system.

- Remove front heat shield.

- Loosen front part of rear heat shield.
- Unbolt selector housing from body.
- Swing gear stick housing down and remove with selector cables.

2.6 - Removing and installing selector mechanism 69

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Installing

Installation is carried out in the reverse sequence, when doing this note the following:

- -> Smear a small amount of polyurea grease in recesses of cable locking mechanism -A- and gate cable
locking mechanism -B-.

Note:

The seals -arrows- outside the recess must be grease free.

- -> Press gear selector cable onto gearbox selector lever and gate selector cable onto relay lever (arrows).

Adjusting selector mechanism => Page 70 .

Tightening torques

Selector housing to body 25 Nm

Cross support to body 25 Nm AG. Volkswagen AG d
agen
Selector cable spt. brkt to gearbox 25 Nm olksw
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2.7 - Adjusting gear selector mechanism from 10.99 s

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du

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ility
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es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
m

Special tools and workshop equipment required

atio
om

n in
or c

◆ T10027 Pin
thi
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sd
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Notes:
cu
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f

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t.
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The following points are essential to ensure correct selector adjustment: ht. Cop py
rig
rig ht
py by
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Prote AG.

70 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
◆ Moving parts of selector mechanism and transmission elements must be in proper condition.
◆ Selector mechanism must move freely.

The gearbox, clutch and clutch mechanism must also be in proper condition.

• Gearbox in neutral position.

- -> Secure locking mechanism on gear selector cable and gate selector cable by pulling forwards until stop
(arrow -1-) and then turning to left to lock (arrow -2-).

AG. Volkswagen AG d
agen oes
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pt
du

an
itte

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-> Set selector shaft as follows:

erm

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ility
ot p

wit

- Press selector shaft down (direction of arrow -1-).

, is n

h re

- Turn right-angle piece -A- in direction of arrow -2- when pressing selector shaft down.
hole

spec

- Pull the gear stick cover off the centre console.

es, in part or in w

- Pull rubber cover towards gear stick knob, if part of original equipment.
t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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f

en
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t.
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Cop py
t. rig
gh
-> Set gear stick as follows:
ht
pyri by
Vo
co lksw
by
cted agen
- Select neutral with gear stick.
Prote AG.

2.7 - Adjusting gear selector mechanism from 10.99 71

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Then guide pin T10027 through hole -A- and into hole -B-.

- -> Now turn locking mechanism on gear selector cable and gate selector cable to right onto stop (direction
of arrow).

The spring presses the locking mechanism into normal position.

- -> Now turn right-angled piece -A- back to original position (direction of arrow).
AG. Volkswagen AG d
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urposes, in part or in wh

t to the co

- -> The selector shaft must now be able to be moved (in direction of arrow).
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

72 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
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rise nte
- -> Pull pin T10027 out of holes -A-ut and -B-.
ho eo
ra
- Clip cover into frame. ss a c

ce
e
nl

pt
du

Functional check

an
itte

y li
erm

ab
• The gear stick lever must rest in the 3rd/4th gear gate with gearbox in neutral.

ility
ot p

wit
, is n

h re
- Operate clutch.
hole

- Select all gears several times. Pay particular attention to the operation of the reverse gear lock.

spec
es, in part or in w

t to the co
Should a gear fail to engage smoothly after repeated selection, the selector shaft play (lift) should be checked
as follows:

rrectness of i
- Engage 1st gear.
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
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f

en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- Press gear stick to left onto stop and release.
- At the same time observe selector shaft in gear box (2nd mechanic).
- -> When moving the gear stick the selector shaft must move approx. 1 mm (in direction of arrow).
- If this is not the case, adjust selector mechanism =>Page 70 .

2.7 - Adjusting gear selector mechanism from 10.99 73

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

3 - Removing and installing gearbox

3.1 - Removing and installing gearbox

AG. Volkswagen AG d
agen oes
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d by ara
ise nte
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aut ra
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ce
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nl

pt
du

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erm

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ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
a

Special tools and workshop equipment required

iv

o
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rp

cu
o

m
f

◆ 10-222 A Support
en
ng

t.
yi Co
◆ 10-222 A/1 Support Cop py
◆ V.A.G 1383 A Gearbox jack
t. rig
gh ht
yri
◆ 3282 Gearbox support
p by
o Vo
by c lksw
◆ 3282/8 Adjustment plate Prote
cted AG.
agen
◆ 3282/48 Pin (Qty. 3)
◆ 3282/59 Support
◆ 3336 Gearbox lifting beam

74 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

G. Volkswagen
Special tools and workshop
lksw
agenequipment required
A AG do
es n
o ot g
yV ua
db
◆ V.A.G 1331
or
isTorque
e wrench ran
tee
h
ut or
ac
sa
Removing
s

ce
e
nl

pt
du

- Check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.

an
itte

y li
- With the ignition switched off disconnect the battery earth strap.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion

- Remove cover from engine.

c

in t
or

- Remove air hoses between air cleaner and turbocharger.

his
ate

- Remove connecting pipe between charge air cooler and intake manifold pressure hose.
do
priv

cum
for

en
g

=> Repair group 21; Removing and installing parts of turbocharger Removing and installing parts of turbo‐
n

t.
yi Co
charger Cop py
t. rig
gh ht
yri by
- -> Pull connector off road speed sender (arrow 1).
cop Vo
by lksw
cted agen
Prote AG.

- Pull off reverse light connector (arrow 2).

- Disconnect all other electrical connections and earth wires from gearbox and from the engine/gearbox se‐
curing bolts.
- -> Unclip hose -A- from cable support bracket.

3.1 - Removing and installing gearbox 75

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Remove cable support bracket from gearbox (arrows).

Vehicles with gear selector mechanism up to 09.99

- -> Remove balance weight -A- and gear selector cable -B- from gear selector lever.
- Take off gear selector cable with washer and square nut (self-locking).
- Pull gate selector cable off actuating arm/relay lever -C- to do this lift lug in direction of arrow.

Vehicles with gear selector mechanism from 10.99

AG. Volkswagen AG d
agen oes
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- -> Pull off gate selector cable -A- with relay lever, remove
ss a circlip -arrow 1- to do this. c
- Remove gear selector cable -B- with gearbox selector lever, remove nut -arrow 2- to do this.

ce
le
un

pt
- Tie selector cable with gearbox selector lever and gate selector cable with relay lever up.

an
d
itte

y li
erm

ab
Continuation for all vehicles

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

- -> Remove slave cylinder place to side and secure with wire, do not disconnect pipes.
thi
te

sd
iva

o
r

Note:
p

cum
r
fo

en
ng

t.
yi
Do not depress clutch pedal.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

76 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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ss c

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le
un

pt
an
d
itte

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- -> If fitted remove connector mounting plate -A-.
erm

ab
- Remove bolt (arrow) on engine console/sub-frame, right.

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n
- -> Disconnect engine carrier at front console.

thi
te

sd
a

- If fitted remove retaining bracket for coolant hose, coolant pipe and securing plate for electrical connections
iv

o
pr

c
from front of console.

um
r
fo

- Remove coolant system expansion reservoir and lay to one side.

en
ng

t.
yi Co
Cop py
t.
Note:
rig
gh ht
pyri by
Vo
o
by c lksw
Do not open cooling system.
cted agen
Prote AG.

- -> Remove hexagon bolt -A- from left hand hand assembly mounting -B-.

- Remove earth strap at engine/gearbox upper securing bolt.

- Remove engine/gearbox upper securing bolts.
- If there are hoses and cable connections in area of engine mounting eye for support 10-222A, remove these
now.

3.1 - Removing and installing gearbox 77

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

- -> Fit support bar 10-222A together with legs 10-222 A/1.
- Take weight of engine/gearbox assembly on the spindles.
- If not already removed, remove wiring and cable from gearbox.
- Remove insulation tray below engine/gearbox, if fitted.
- Remove charge air cooler.

=> Repair group 21; Removing and installing parts of turbocharger Removing and installing parts of turbo‐
charger

- Remove power assisted steering pipe bracket from starter.

- Remove starter.

=> Repair group 27; Removing and installing starter. Removing and installing starter.

n AG. Volkswagen AG do
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- Remove front console.

un

pt

- Separate exhaust system in front of catalyst.

an
d
itte

y li

- -> Remove vibration damper -A- from sub-frame. Mark installation position.
rm

ab

- Remove right hand inner constant velocity joint protective cover from engine if fitted.
pe

ility
ot

- Disconnect drive shafts from drive flanges and tie-up.

wit
, is n

- When doing this do not damage surface protection.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

- -> Removing gearbox console -A- from gearbox.

um
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

78 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
To do this remove gearbox console securing bolt -B- as follows:
- Lift engine/gearbox assembly via both spindles until the exhaust system contacts the heat shield; ensure
that selector cable support bracket is not jammed.
- Push engine/gearbox assembly forwards (2nd mechanic required) and remove lower gearbox console se‐
curing bolt -B-.
- Then tie drive shaft up as high as possible. When doing this ensure sufficient clearance between constant
velocity joint and flange shaft.

- Lower engine/gearbox assembly via both spindles to previous position and push as far as possible to the
right.

n AG. Volkswagen AG do
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itte

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erm

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ility
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wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness

Note:
o
cial p

f in

Do not damage P.A.S. pipe when moving engine/gearbox assembly.

form
mer

atio

- Then slightly lower engine/gearbox assembly via left spindle of support bracket 10-222A.
om

- -> Remove flywheel small cover plate -A- behind the right-hand flanged shaft (arrows).
n
c

i
or

- Remove lower flywheel cover plate, if part of original equipment.

thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

- Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/8 for "02A" gearbox and support
elements as follows:
- Place adjustment plate 3282/8 on gearbox support 3282. (Adjustment plate only fits in one position).
- Align arms of gearbox support according to holes in adjustment plate.

3.1 - Removing and installing gearbox 79

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- -> Bolt on support elements -A-, as illustrated, on adjustment plate.

- -> Place gearbox jack under vehicle, arrow symbol -B-ge(=> AGIllustration
. VolkswagenV34-2670)
AG do on adjustment plate points
a n
to front of vehicle. Volksw es n
ot
- Align adjustment plate parallel to gearbox and ed lock safety supports on gearbox. ran
by gu
a
- Remove lower engine/gearbox securingthobolt. ris tee
or
- Press gearbox off dowels and carefullys au lower. ac
s

ce
le

Note:
un

pt
an
d
itte

y li
rm

ab
Do not damage P.A.S pipe when lowering gearbox.
pe

ility
ot

wit
, is n

- Press engine forward slightly when lowering gearbox.

h re
- Continually correct the gearbox position via the gearbox jack spindles.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi
Transporting the gearbox
Co
Cop py
t. rig
gh ht
yri
- -> Bolt gearbox lifting device 3336 to clutch housing.
p by
co Vo
by lksw
cted agen
Prote AG.

- -> Set support arm on sliding piece with locking pin (arrow).

80 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
No. of holes visible = 5
- Lift gearbox with workshop crane and gearbox lifting device 3336.
- Place gearbox, for example onto transport container.

Installing

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Notes:
ce
le
un

pt
an
d

◆ -> Before installing gearbox press clutch release lever towards gearbox housing and secure with assembly
itte

y li
erm

ab

pin, assembly bolt or M 8 x 35 bolt. Remove after gearbox has been installed. The hole will then be sealed
ility
ot p

by the 3rd cable support bracket securing bolt or plugged.

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
e

◆ -> When replacing gearbox, the senders for speedometer (Fig.), gear selector and relay lever must be
t

sd
va

transferred to new assembly.

i

o
pr

cum
r
fo

en
ng

t.
- Clean input shaft splines and lightly grease with G000 100 grease.
yi Co
Cop py
t. rig
gh ht
The clutch plate must be able to slide lightly to and fro on the input shaft.
pyri by
Vo
o
by c lksw
cted agen
- Check whether dowel sleeves for aligning engine/gearbox are fitted in cylinder block, install if necessary.
Prote AG.

- Ensure that the intermediate plate is correctly positioned on engine.

3.1 - Removing and installing gearbox 81

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Assemble gearbox jack with gearbox support 3282, adjustment plate 3282/8 for "02A" gearbox and support
elements as follows:

- Place adjustment plate 3282/8 on gearbox support 3282. (Adjustment plate only fits in one position).
- Align arms of gearbox support according to holes in adjustment plate.
- -> Bolt on support elements -A-, as illustrated, on adjustment plate.

- Place gearbox on gearbox jack.

- Align adjustment plate and gearbox parallel with one another and lock safety supports on gearbox.
- -> Place gearbox jack under vehicle, arrow symbol -B- (=> Illustration
n AG.V34-2670
Volkswagen Aon
G dprevious page) on ad‐
justment plate points to front of vehicle. lkswage oes
not
Vo
- Insert gearbox. ed
by gu
ara
n ris tee
tho or
Note: ss
au ac
ce
e
nl

pt

Do not damage P.A.S pipe.

du

an
itte

y li
erm

ab

- Install lower engine/gearbox securing bolts.

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
r

- Install upper engine/gearbox securing bolts.

o

his
te

- -> Install gearbox console -A-.

a

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
82 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Install gearbox console securing bolt -B- as follows:

- Lift engine/gearbox assembly via both spindles and push towards front end (2nd mechanic required) and
then install lower gearbox console securing bolt -B-.

- Install front console.

- Install starter.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
=> Repair group 27; Removing and installing starter. Removing and installing starter.
t. rig
gh ht
pyri by
Vo
co lksw
by
- Align engine/gearbox in installation position. cted agen
Prote AG.
- Install power assisted steering pipe bracket on starter.
- -> If it was removed install small cover plate -A- behind right-hand drive flange (arrows).
- If it was removed install large cover plate for clutch.
- Fit drive shafts to gearbox.

=> Running gear, axles, steering; Repair group 40; Servicing drive shafts, Removing and installing drive shafts
Servicing drive shafts, Removing and installing drive shafts

- Bolt right-hand drive shaft protective cover to engine if necessary.

3.1 - Removing and installing gearbox 83

 AG. Volkswagen AG d
agen oes
olksw not
Polo Estate 1998 ➤ d byV gu
ara
e
5-speed manual gearbox 02J horis - Edition 01.2000 nte
eo
aut ra
s c
- -> Screw balance weight -A- to subframe.
s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

- Install charge air cooler and connecting pipes between charge air cooler and inlet manifold pressure hose.
m

a
com

t
=> Repair group 21; Removing and installing parts of turbocharger Removing and installing parts of turbo‐

ion in
charger
r
te o

thi
s
iva

do
- -> Insert hexagon bolt on gearbox assembly mounting (arrow).
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- -> Install bolt (arrow) on engine console/sub-frame, right. Fit connector mounting plate -A-, if fitted.

- -> Install front console securing bolt to engine mounting.

84 34 - Controls, Housing
 AG. Volkswagen AG d
agen oes Polo Estate 1998 ➤
olksw not
yV gu
ed b 5-speed manual gearbox
ara
nte
02J - Edition 01.2000
ris
tho eo
au ra
c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
- -> Remove support bracket 10-222A
l purpos

nform
Warning!
ercia

Do not remove support bar 10-222A until the bolts securing the left-hand gearbox console have been tightened
m

at
to torque setting.
om

ion
c

in t
or

his
e

- Align engine/gearbox mountings stress-free by shaking assembly and tighten to tightening torque.
at

do
priv

cum
or

=> Repair group 10; Removing and installing engine. Removing and installing engine.
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

- -> Install slave cylinder -arrows-.

- -> Connect speedometer sender connector (arrow 1).

- Connect reverse light connector (arrow 2).
- Install air hoses between air cleaner and turbocharger.

3.1 - Removing and installing gearbox 85

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

- -> Install cable support bracket on gearbox -arrows-, if necessary push hose -A- onto cable support bracket.

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r

Vehicles with gear selector mechanism up to 09.99

te o

thi
s
iva

do
r
rp

- -> Install gear selector cable -B- and balance weight -A- on gear selector lever.

cum
fo

- Fit gate selector cable on follower/relay lever -C- to do this lift lug in direction of arrow.

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Vehicles with gear selector mechanism from 10.99

- -> Fit gear selector cable -B- with gearbox selector lever (arrow 2).
- Fit gate selector cable -A- with relay lever and secure with a circlip (arrow 1).

Continuation for all vehicles

- Secure coolant system expansion reservoir.

- Reconnect earth strap to battery.

Note:

Note radio coding for vehicles with coded radio.

86 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Checking gearbox oil =>Page 88 .
- Install insulation tray below engine/gearbox, if fitted.
- Adjusting gear selector mechanism up to 09.99 => Page 52 .
- Adjusting gear selector mechanism from 10.99 => Page 70 .
- Install engine cover.

Tightening torques

-> Gearbox to engine

Item Bolt Qty. Nm

1 M 12 x 55 3 80
2 1) M 12 x 150 2 80
3 2) M 10 x 50 3 60
4 3) M 7 x 12 2 10
5 4) M 7 x 12 1 10

1) Also starter to gearbox agen

AG. Volkswagen AG d
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olksw not
V gu
by
2) Only on engines withisan e aluminium sump,
d ara
nte
or eo
h
ut ra
3) Large cover plate
ss a
for flywheel only on engines with heat steel sump c (sump painted black)
ce
le
un

pt

4) Small cover plate for flywheel

an
d
itte

y li
rm

ab

Items A + B - Dowel sleeves

pe

ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
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thi
s
iva

-> Assembly mountings

do
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rp

cum
fo

en
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Pos. Bolt Qty. Nm

t.
yi Co
op py
1 M 10 x 30 1 50
t. C rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

3.1 - Removing and installing gearbox 87

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Pos. Bolt Qty. Nm

2 M 10 x 45 2 50

Left gearbox console to gearbox (arrow) 25 Nm

Right engine console to assembly carrier 60 Nm

Drive shaft protective cover to engine 35 Nm

Selector cable spt. brkt to gearbox 25 Nm
Selector cable bolt to gearbox selector lever 25 Nm
Balance weight to gearbox selector lever 30 Nm

4 - Checking gear oil

4.1 - Checking gear oil

Gear oil specification => Page 2

- Remove insulation tray below engine/gearbox, if fitted.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio

- -> Remove plug (arrow) to check oil

om

n in
or c

The oil level is correct when the gearbox is full to the lower edge of the filler hole.
thi
te

sd
iva

- Fit plug (arrow).

o
r
rp

cu
o

m
f

en
ng

t.
When filling with new oil note following:
yi Co
Cop py
ht. rig
- Remove plug (arrow). py
rig by
ht
- Top up oil to lower edge of filler hole. co Vo
by lksw
- Fit plug (arrow).
cted agen
Prote AG.
- Start engine, engage gear and allow gearbox to turn for approx. 2 minutes.
- Switch off engine and remove plug (arrow).
- Top up oil to lower edge of filler hole again.

88 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Fit plug (arrow).

5 - Dismantlingolandagenassembling gearbox
AG. gen AG Volkswa
does
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yV gu
db ara
ise
5.1 - Dismantling
tho
r and assembling gearbox nte
eo
s au ra
c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5.2 - Overview
1 1st gear
2 2nd gear
3 3rd gear
4 4th gear
5 5th gear
6 Gearbox housing
◆ Servicing => page 118
7 Selector mechanism
◆ (Selector forks)
◆ Dismantling and assembling
=> Page 139

4.1 - Checking gear oil 89

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

8 Input gear for 1st and reverse gear

n AG. Volkswagen AG do
lkswage es n
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d ran
ir se tee
tho
u or
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ss
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re

9 Input shaft
hole

spec

◆ Dismantling and assembling => page 146

es, in part or in w

t to the co

10 Output shaft
◆ Dismantling and assembling => Page 165
11 Differential
rrectness of i

◆ Dismantling and assembling => page 206

l purpos

12 Clutch housing
◆ Servicing => Page 118
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

90 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

5.3 - Assembly overview

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
I - Removing and installing cover for gearbox housing and 5th gear => Page 92
rrectness of i
l purpos

II - Dismantling and assembling gearbox housing and shift mechanism => Page 95

III - Dismantling and assembling input shaft, output shaft, differential and selector forks => Page 97
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5.3 - Assembly overview 91

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

5.4 - Removing and installing cover for gearbox

olkswa
housing and 5th gear
n AG. V gen AG
wage does
Volks not
gu
by ara
ed nte
oris eo
th
au ra
c
ss

ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 Hexagon bolt, 10 Nm
◆ For gearbox housing cover
2 Gearbox housing cover

Note:

If the gearbox cover is fitted with the gearbox installed, check oil level as follows:

- Fill with oil up to lower edge of filler hole and fit filler plug.
- Start engine, engage gear and allow gearbox to turn for approx. 2 minutes.
- Switch off engine and top up gearbox oil to lower edge of filler hole again.

92 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion

3 Gasket
c

in t
or

his
e

4 Torx socket head bolt M10, 80 Nm

at

do
riv

◆ Fitted piece on bolt head holds saucer spring washer in position

p

cum
for

5 Dished spring
en
ng

t.
yi Co
◆ Installing => Page 116 Cop py
t. rig
6 Socket head bolt, 25 Nm
gh ht
pyri by
Vo
o
by c
◆ For pivot pin to gearbox housing
lksw
cted agen
Prote AG.
7 Pivot pin
8 5th gear selector fork
◆ Dismantling and assembling
=> Page 139
◆ Adjusting =>Page 116

5.4 - Removing and installing cover for gearbox housing and 5th gear 93
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
9 5th gear locking collar
ercia

or
◆ Installation position =>Page 114

m
m

atio
◆ Adjusting =>Page 116
om

n in
c

10 Synchro-hub with 5th gear and synchronizing ring

or

thi
te

◆ Dismantling and assembling sd

iva

o
r

=> Page 158

rp

cu
o

m
f

11 Needle roller bearing

en
ng

t.
yi Co
12 5th speed gear wheel Cop py
t. rig
gh
◆ Installation position => page 113
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

94 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

5.5 - Removing and installing gearbox housing and selector mechanism

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1 Countersunk head bolt, 25 Nm

2 Flanged shaft with spring
◆ Removing and installing => Page 104
◆ Assembling=> from page 206
3 Torx socket head bolt, 30 Nm
◆ For reverse shaft support
◆ Self-locking
◆ Always renew
4 O ring
◆ Always renew
5 Pivot pin
6 Bolt, 25 Nm

5.5 - Removing and installing gearbox housing and selector mechanism 95

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

7 Bolt, 25 Nm
wit
, is n

8 Cover plate
h re
hole

9 Gearbox housing
spec
es, in part or in w

◆ Servicing => page 118

t to the co

10 Clutch housing
◆ Servicing => page 118
rrectness of i

11 Hexagon bolt, 25 Nm then turn 90°further

12 Selector mechanism
l purpos

◆ Dismantling and assembling up to 09.99 =>from Page 128

◆ Dismantling and assembling from 10.99 =>from Page 133
nform
ercia

13 Hexagon bolt, 25 Nm
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

96 34 - Controls, Housing
 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Polo Estate 1998 ➤
u
ss
a
5-speed manual gearboxac02J - Edition 01.2000

ce
e
nl

pt
5.6 - Removing and installing input shaft, output shaft (pinion shaft), differential and selector

du

an
itte

y li
forks

erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 Differential
◆ Dismantling and assembling => page 206
2 Oil seal
◆ Qty. 4
◆ Always renew
3 Output shaft
◆ Dismantling and assembling => Page 165
4 Reverse shaft support
◆ Dismantling and assembling => Page 200

5.6 - Removing and installing input shaft, output shaft (pinion shaft), differential and selector

forks 97
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5 Reverse shaft
◆ Dismantling and assembling => Page 198
6 Input shaft
◆ Dismantling and assembling => page 146
7 Reverse gear selector fork
◆ Dismantling and assembling
=> Page 139
◆ Installation position => Page 109
8 Torx socket head bolt, 25 Nm
9 Selector mechanism
◆ (Selector forks)
◆ Dismantling and assembling
=> Page 139
10 Clutch housing
◆ Servicing => Page 118

98 34 - Controls, Housing
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
11 Hexagon nut, 25 Nm and then turn 90° further

s
◆ 4 nuts for bearing support

s o
cial p

f
12 Flange shaft with spring

inform
◆ Removing and installing => Page 104
mer

◆ Assembling=> from page 206 atio

om

n
13 Cone head bolt, 25 Nm
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5.6 - Removing and installing input shaft, output shaft (pinion shaft), differential and selector

forks 99
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Dismantling and assembling gearbox housing cover, gearbox housing, selector mechanism, input shaft, output
shaft (pinion shaft), differential and selector forks

Special tools and workshop equipment required

◆ VW 309 Holding plate

◆ VW 353 Gearbox support
◆ VW 295 Drift
◆ VW 244 B Fitting sleeve
◆ V. A. G. 1416 Hot air blower
◆ V.A.G 1331 Torque wrench
◆ Studs M 8 x 100 mm

100 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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Special tools and workshop equipment required

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◆ 1 - Two-arm puller Kukko 20/10
ole,

spec
urposes, in part or in wh

with Matra V170 hooks

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◆ V.A.G 1332 Torque wrench t. C rig
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5.7 - Assembly sequence 101

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Dismantling
- -> Mount gearbox on repair stand.
- Drain gearbox oil.

- Remove clutch release lever and release bearing => Page 28 .

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- Remove guide sleeve => Page 28 . t. Cop py
- -> Remove gearbox housing cover (arrow).
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102 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
G. Volkswagen AG d
- -> Remove 5th gear selector fork (arrows) ksw
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- Remove spring and locking pieces from locking collar. y Vol gu
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- Pull off 5th gear selector fork with locking collar.
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- Then place locking collar without selector afork
ut onto synchro hub.
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- -> Remove bolts -A- for synchro-hub and 5th gear, to do this select 5th (arrow 1) and 1st gear (arrows 2 and
3).

nf
ercia

o
- After engaging both gears the input shaft and output shaft are locked, synchro-hub and gear wheel cannot

rm
m

atio
turn. Both bolts can now be loosened.
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- -> Pull off synchro-hub and 5th gear wheel and remove together with needle roller bearing.

A - Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks.
B - Hexagon bolt M10 x 20

5.7 - Assembly sequence 103

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

- -> Pull off 5th gear

A - Two arm puller e.g. Kukko 20/10 with Matra V/170 hooks. AG. Volkswagen AG d
agen
B - Hexagon bolt M10 x 20 Volksw
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Removal sequence: d by gu
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- Assemble two arm puller and centralize bythturning screw (arrow). nte
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- Pull gear wheel off with two arm puller, first
s a heat with hot air blower V.A.G 1416 if necessary.
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c s

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nl

Note:

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When pulling off the gear wheel ensure that the hooks do not bend outwards, if necessary tighten screw (arrow).
After 5th gear wheel has been removed check for damage.

- -> Remove both flange shafts.

- Take out flanged shafts along with springs, thrust washers and tapered rings.

104 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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- -> Remove orisboth reverse shaft support bracket boltsan(arrows).
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tee
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nl

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es, in part or in w

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- -> Remove selector shaft with selector mechanism cover, to do this place selector shaft in neutral position.
Then remove bolts -arrows- and pull selector shaft out of the gearbox housing.
nf
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5.7 - Assembly sequence 105

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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es, in part or in w

t to the co
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- -> Remove cover plate -A- and pivot pins -B- from underside of gearbox.

nform
mercia

a
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tion in
r
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- -> Remove pivot pins -A- on top side of gearbox and gearbox housing to clutch housing securing bolts -B-
in area of differential.

106 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

- -> Remove bolts -A-, from inside clutch housing for securing clutch housing to gearbox housing.

Note:

Do not remove nuts -B- for output shaft bearing support.

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- -> Take-off gearbox housing, if necessary carefully lever up all round and alternating between sides on the
protruding housing flange (arrows), being careful not to damage sealing surfaces.
l purpos

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mercia

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5.7 - Assembly sequence 107

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

- -> Remove selector forks -A- together with selector plates.

- Unscrew bolt for selector mechanism for reverse gear -B-.
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mer

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- Remove nuts for output shaft bearing support (=>Item -B-, Illustration N34-0060, Page 107 ) C py
t. rig
- -> Remove reverse gear -A-, input shaft -B- and output shaft -C- one after the other from clutch housing.
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- Take out differential.
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108 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Assembling

- Install differential.

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- -> Always renew sealing rings (arrows) for output shaft bearing support.

rrectne
Note:

ss o
The illustration only shows 3 of the 4 sealing rings.
cial p

f inform
mer

- Install input shaft, output shaft and reverse shaft together.

atio
m

- Tighten nuts for output shaft bearing support.

o

n
c

- Clean locking fluid remnants from threads in the reverse shaft support (arrow Illustration V34-2293, Page i
or

n thi
111 ). The remnants can be removed using a tap.
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5.7 - Assembly sequence 109

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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- Install reverse shaft support.

h re
- Install reverse gear selector mechanism.
hole

spec
es, in part or in w

-> Installation position reverse gear

t to the co
- Install selector forks together with selector plates.

rrectness of i
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- -> Screw M 8 x 100 mm studs -A- into reverse shaft support so that the shaft is aligned after fitting gearbox
housing.

110 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Align selector plates.

Note:

The selector segments must be positioned in the grooves on the locking collars.

- Fit gearbox housing.

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Install reverse shaft support bolts (arrow) as follows:

- -> Insert bolt -a-, remove stud (=> Illustration V34-2008), insert bolt -b- and hand tighten.

nform
mercia

Tightening sequence:

a
com

tio
1 - Bolt -a- 30 Nm

n in
r

2 - Bolt -b- 30 Nm
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5.7 - Assembly sequence 111

 AG. Volkswagen AG d
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Polo Estate 1998 ➤ by Vol
gu
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5-speed manual gearbox 02J - Edition orise 01.2000 nte
eo
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urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

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om

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- -> Install pivot pin (arrow) for selector forks. To do this align selector mechanism with a screwdriver, so that
the relevant pivot pin can be installed.
- Fit selector shaft cover

-> Install selector shaft as follows:

- Place selector plates in neutral.
- Locate lug (arrow 1) in the recess in gearbox housing. Position selector shaft so that selector finger (arrow
2) is inserted in the selector plates.

112 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Install selector shaft cover.

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-> Installationthposition
oris
5th gear wheel eo
au ra
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pt

The circumferential groove (arrow) faces to gearbox housing.

du

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erm

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ility
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es, in part or in w

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rrectness of i
l purpos

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- -> Knock-on 5th gear.

5.7 - Assembly sequence 113

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Checking 5th gear synchro-ring

- -> Before installing 5th gear wheel and synchro-ring press the synchro-ring onto the cone of the gear wheel
and measure gap -a- with a feeler gauge.

Gap -a- New Wear limit

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5th gear 1.1 ... 1.7 mm lkswagen A
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- Install 5th gear wheel owith
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- Place 5th gear synchro-ring
aut
h on gear wheel or
ac
- Assembly 5th gear ss synchro-hub/locking collar before installing => Page 159 .
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cial p

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mer

-> Installation position 5th gear synchro-hub/locking collar

atio
om

n
c

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or

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e

The pointed teeth of the locking collar (arrow 1) and the high shoulder of the synchro-hub (arrow 2) face the
t

sd
va

gearbox housing.
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Prote AG.

114 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
The syncro-hub mountings (arrow 3) align with the synchro-ring cast locking pieces (arrows on illustration
N35-0018 => Page 115 ).

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es, in part or in w

-> 5th gear synchro-ring with cast locking pieces (arrows)

t to the co
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- -> Knock-on 5th gear synchro-hub
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When driving on ensure synchro-ring is free to move.
agen
Prote AG.

5.7 - Assembly sequence 115

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Screw-in securing bolts for synchro-hub and 5th gear wheel.

-> Installation position of dished spring for gear wheel and 5th gear synchro-hub securing bolts:
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The outer diameter (concave side e-arrows-)
d byV faces 5th gear. gu
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rrectness of i
- -> Tighten bolts -A- for synchro-hub and 5th gear. To do this select 5th (arrow 1) and 1st gear (arrows 2 and
l purpos

3).
- After engaging both gears the input shaft and output shaft are locked, synchro-hub and gear wheel cannot

nform
ercia

turn. Both bolts can now be tightened.

- Install 5th gear selector fork.
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-> Adjusting 5th gear:

- Engage 5th gear. Loosen bolt -1-. Press locking collar and selector fork jaws in direction of arrow, then
tighten bolt -1- to 25 Nm.

• Check measurement :

116 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
It must not be possible to slide a 0.2 mm feeler gauge between locking collar and gear wheel. If necessary
repeat adjustment.

- Disengage 5th gear. Locking collar must now be

AG. Vin
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swagneutral
en AG position. Synchro-ring must move freely.
agen does
- Select all gears. olksw not
- Fit gearbox housing cover byV gu
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ility
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es, in part or in w

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nf
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py by
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- -> Install flanged shafts along with springs, thrust washers and tapered rings.
Prote AG.

- Fit release bearing guide sleeve => Page 28 .

- Fit clutch release lever and release bearing => Page 28 .

5.7 - Assembly sequence 117

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

6 - Servicing gearbox housing and clutch housing

6.1 - Servicing gearbox housing and clutch housing

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ility
ot

Special tools and workshop equipment required

wit
, is n

h re
hole

◆ VW 295 Drift
spec

◆ VW 295a Adapter
es, in part or in w

t to the co

◆ VW 447 H Press plate

◆ VW 512 Press disk
◆ 2040 Tube
rrectness of i

◆ VW 454 Press piece

l purpos

nform
mercia

a
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r
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118 34 - Controls, Housing

Prote AG.
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
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t to the co
rrectness of i
l purpos

nform
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a
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tion in
r
te o

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fo

en
ng

t.
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cted agen
Prote AG.

Special tools and workshop equipment required

◆ VW 222 A Drift
◆ VW 353 Gearbox support
◆ 3066 Spindle from assembly tool
◆ 3124 Press piece
◆ V.A.G 1331 Torque wrench
◆ 1 - Kukko 21/1 Internal puller
◆ 4 - Kukko 22/1 Counter-support

6.1 - Servicing gearbox housing and clutch housing 119

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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ility
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es, in part or in w

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1 Gearbox housing
◆ If replaced: Adjust input shaft and differential => Page 220
rrectness of i

2 Needle roller bearing

l purpos

◆ For output shaft

◆ Removing => Fig. 1
◆ Installing and securing
nform
ercia

=> Fig. 2
m

at

3 Oil filler plug, 25 Nm

om

ion
c

◆ Without magnet
in t
or

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e

4 Outer race/taper roller bearing

at

do
riv

◆ For output shaft

p

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or

◆ Removing and installing

f

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ng

t.
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=> Page 177
Co
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◆ If replaced: Adjust output shaft
. C rig
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rig
=> Page 195 py by
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◆ For output shaft
◆ Adjustment overview
=> Page 220

120 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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6 Shim
t

sd
iva

o
r

◆ For input shaft

rp

cu
o

m
f

◆ Adjustment overview
en
ng

t.
yi
=> Page 220
Co
Cop py
. rig
7 Outer race/taper roller bearing
ht ht
rig by
py
◆ For input shaft
co Vo
by lksw
cted agen
◆ Removing and installing Prote AG.
=> Page 153
◆ If replaced: Adjust input shaft
=> Page 160
8 Outer race/taper roller bearing
◆ For input shaft
◆ Removing and installing
=> Page 157
◆ If replaced: Adjust input shaft
=> Page 160
9 Needle bearing
◆ Removing and installing
=> Page 201

6.1 - Servicing gearbox housing and clutch housing 121

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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, is n

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es, in part or in w

t to the co
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nform
mercia

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tion in
r
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thi
s
iva

do
r
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cum
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10 Dowel sleeve
en
ng

t.
yi Co
◆ (Qty. 2) t. Cop py
rig
11 Starter bush gh ht
pyri by
Vo
o
◆ Pulling out => Fig. 5 by c lksw
cted agen
◆ Knocking in => Fig. 6 Prote AG.
◆ Can be replaced without removing gearbox
12 Clutch housing
◆ If replaced: =>Adjustment overview, Page 220
13 Guide sleeve
◆ With input shaft seal and a vulcanised O ring
◆ Knocking-out oil seal => Fig. 3
◆ Knocking-in oil seal => Fig. 4
◆ Remove guide sleeve to change the oil seal
◆ If damaged replace guide sleeve and O-ring together

122 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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ility
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, is n

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es, in part or in w

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op
14 Socket head bolt, 20 Nm
C py
t. rig
gh ht
◆ Self-locking pyri by
Vo
co
◆ Always renew
by lksw
cted agen
Prote AG.
15 Oil seal
◆ Renewing => Page 203
16 Sleeve
◆ For oil seal (Item 15 )
◆ Removing => Fig. 7
◆ Installing => Fig. 8
17 Speedometer drive, 30 Nm
18 Oil drain plug, 25 Nm
◆ Without magnet
19 Outer race/taper roller bearing
◆ For differential
◆ Pressing in and out
=> Page 206
◆ If replaced: Adjust differential
=> page 221

6.1 - Servicing gearbox housing and clutch housing 123

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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es, in part or in w

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20 Magnet
l purpos

◆ Held in place by housing joint surface

21 Outer race/taper roller bearing
nform
ercia

◆ For differential
◆ Pressing in and out
m

a
com

ti

=> Page 206

on in

◆ If replaced: Adjust differential

r
te o

thi

=> page 221

s
iva

do
r

22 Shim
rp

cum
fo

◆ For differential
en
ng

t.
yi Co
◆ Adjustment overview Cop py
=> Page 220 ht. rig
rig ht
py by
23 Oil seal co Vo
by lksw
cted agen
◆ Renewing => Page 203 Prote AG.

124 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
n AG. Volkswagen AG do
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du

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itte

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ility
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, is n

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hole

spec
es, in part or in w

t to the co
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l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

do
priv

cum
for

en
ng

t.
yi Co
op
-> Fig.1 Knocking-out needle roller bearing.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

-> Fig.2 Knocking needle roller bearing in onto stop

- Secure needle roller bearing in gearbox housing at three points (120° offset) with a punch.

6.1 - Servicing gearbox housing and clutch housing 125

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.3 Knocking oil seal out of guide sleeve.

AG. Volkswagen AG d
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tho eo
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un

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an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

-> Fig.4 Knock oil seal into the guide sleeve onto stop.
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

126 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.5 Pulling out starter bush.

A - Internal extractor 12 ... 14.5 mm, e.g. Kukko 21/1 AG. Volkswagen AG d
agen oes
olksw not
V
B - Counter support. e.g. Kukko 22/1 ed by gu
ara
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itte

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ility
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is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness
-> Fig.6 Knocking in starter bush.

o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

-> Fig.7 Lever out sleeve -arrow- with screwdriver

-> Fig.8 Pulling sleeve in

A - Screw threaded rod from assembly tool 3066 into

differential threaded piece
B - Nut M12 with washer

- Pull sleeve in onto stop with thrust piece 3124 by turning on nut -B-.

6.1 - Servicing gearbox housing and clutch housing 127

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Note:

When gearbox is dismantled press sleeve in with thrust piece 3124 onto stop.

7 - Dismantling and assembling gearbox selector mechanism up to 09.99

7.1 - Dismantling and assembling gearbox selector mechanism up to 09.99

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ility
ot p

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es, in part or in w

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m

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r
rp

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m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Special tools and workshop equipment required

◆ VW 401 Thrust plate

◆ VW 408 A Press tool
◆ VW 423 Tube
◆ VW 439 Guide pin
◆ VW 447 i Thrust plate
◆ 1 - Kukko 21/3 Internal puller

128 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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ss c

ce
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nl

pt
du

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itte

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erm

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ility
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, is n

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es, in part or in w

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rrectness of i
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1 Selector shaft
t.
yi Co
op py
2 Stop ring t. C rig
gh ht
yri by
3 Ball sleeve op Vo
by c lksw
cted
◆ Removing => Fig. 1
agen
Prote AG.
◆ Pressing in => Fig. 2
4 Oil seal
◆ Lever out with screwdriver
◆ Installing => Fig. 3
5 Selector mechanism cover
6 Sleeve
◆ The lug points to reverse light switch
◆ Lightly coat lug with MoS2 grease
7 Hexagon nut, 25 Nm
◆ Self-locking
◆ Always renew

7.1 - Dismantling and assembling gearbox selector mechanism up to 09.99 129

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
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8 Housing
pe

ility
ot

◆ For reversing light switch

wit
, is n

h re

9 bolt
hole

spec

10 Cap
es, in part or in w

◆ For gearbox breather

t to the co

11 Sleeve
◆ Drive in onto stop if present as an individual part
rrectness of i

12 Gear selector lever

l purpos

◆ Install so that the master spline aligns with selector shaft

◆ Can be replaced with the selector mechanism installed
◆ Installation position =>Page 43
nform
ercia

13 Relay lever
m

◆ Installation position => Page 43

com

tion in

14 Nut, 15 Nm
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

130 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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15 Actuating arm ss c
ce
e

◆ With axis pin for mounting relay lever

nl

pt
du

◆ Installation position => Page 43

an
itte

y li
erm

16 Bolt
ab
ility
ot p

◆ Press into actuating arm

wit
, is n

17 O-ring
h re
hole

◆ Pull onto actuating arm axis pin

spec
es, in part or in w

18 Spacer
t to the co

◆ Press into relay lever

19 Locking bolt, 40 Nm
rrectness of i

20 End cover
l purpos

nform
mercia

at
om

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c

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or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7.1 - Dismantling and assembling gearbox selector mechanism up to 09.99 131

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.1 Removing ball sleeve from selector mechanism cover

- Before pulling out ball sleeve, destroy plastic cage and remove balls.

A - Internal extractor, e.g. Kukko 21/3, 18.5 ... 23.5 mm

n AG. Volkswagen AG do
lkswage es n
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-> Fig.2 Knocking ball sleeve into selector mechanism cover
ir se
d b ran
tee
tho
u or
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ss
ce
e
nl

pt
du

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itte

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erm

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ility
ot p

wit
, is n

h re
hole

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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

132 34 - Controls, Housing

 n AG. Volkswagen AG do
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or Estate 1998 ➤
u
ss
a
5-speed manual gearbox 02J - Edition ac
01.2000

ce
e
nl

pt
-> Fig.3 Installing oil seal onto stop

du

an
itte

y li
erm

ab
ility
ot p

wit
8 - Dismantling and assembling gearbox selector mechanism from 10.99

, is n

h re
hole

spec
8.1 - Dismantling and assembling gearbox selector mechanism from 10.99
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Special tools and workshop equipment required

◆ VW 401 Thrust plate

◆ VW 408 A Press tool
◆ VW 423 Tube
◆ VW 439 Guide pin
◆ VW 447 i Thrust plate
◆ 1 - Kukko 21/3 Internal puller

7.1 - Dismantling and assembling gearbox selector mechanism up to 09.99 133

 . Volkswagen AG
gen AG does
Polo Estate 1998 ➤ olks
wa not
yV gu
5-speed manual gearbox 02J - Edition
ise
d b 01.2000 ara
nte
r
ho eo
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ce
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nl

pt
du

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itte

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erm

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ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

do
priv

cum
for

en
ng

t.
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Cop py
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pyri by
Vo
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Prote AG.

1 Selector shaft
◆ Revised stop sleeves, which allows the selector shaft to be guided into the 4th gear gate when changing
down from 5th to 4th gear, have been introduced as of gearbox build date 04 09 0 =>Fig. 4
◆ From gearbox build date 06 08 1 additional locking mechanism in end cover =>Fig. 5
2 Stop ring
3 Ball sleeve
◆ Removing => Fig. 1
◆ Pressing in => Fig. 2
4 Selector mechanism cover
◆ With an additional bolt which allows the selector shaft to be guided into the 4th gear gate when changing
down from 5th to 4th gear, have been introduced as of gearbox build date 04 09 0 => Fig. 4

134 34 - Controls, Housing

 AG. Volkswagen AG d
agen oes
ksw not
by Vol
Polo gu Estate 1998 ➤
ara
d
ris5-speed
e manual gearbox 02J - Edition
nte 01.2000
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

5 Reversing light switch, 20 Nm

◆ Lightly coat lug with MoS2 grease
6 Cap
◆ For gearbox breather
7 Relay lever
◆ Installation position => Page 43
8 Bush
9 Oil seal
◆ Lever out with screwdriver
◆ Installing => Fig. 3
10 Circlip

8.1 - Dismantling and assembling gearbox selector mechanism from 10.99 135
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c

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le
un

pt
an
d
itte

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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in

11 Hexagon nut, 25 Nm
r
te o

thi
s

◆ Self-locking
iva

do
r

◆ Always renew
rp

cum
fo

en

12 Gear selector lever

ng

t.
yi Co
op
◆ Install so that the master spline aligns with selector shaft C py
t. rig
◆ Can be replaced with the selector mechanism installed
gh ht
pyri by
◆ Installation position =>Page 43
co Vo
by lksw
cted agen
13 End cover
Prote AG.

◆ From gearbox build date 06 08 1 with locking mechanism for the selector shaft => Fig. 5

136 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.1 Removing ball sleeve from selector mechanism cover

- Before pulling out ball sleeve, destroy plastic cage and remove balls.

A - Internal extractor, e.g. Kukko 21/3, 18.5 ... 23.5 mm

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
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a ac
ss
ce
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un

pt
an
d
itte

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-> Fig.2 Pressing ball sleeve into selector mechanism cover

rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

8.1 - Dismantling and assembling gearbox selector mechanism from 10.99 137
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.3 Installing oil seal onto stop

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
-> Fig.4 Revised selector cover and selector shaft
om

n in
or c

thi
te

sd
a

As of gearbox build date 04 09 0 bolt -2- is installed in selector cover -1-.

iv

o
r
rp

cu
o

m
f

en
ng

Tightening torque
t.
yi Co
Cop py
ht. rig
15 Nm rig ht
py by
co Vo
by lksw
cted agen
In conjunction with this the stop sleeve is fitted with a bridge -3-. Prote AG.

Functional check

When shifting down from 5th gear to 4th gear the bolt -2- guides the selector shaft over bridge -3- into 4th gear
gate.

-> Fig.5 Revised selector shaft and selector cover

From gearbox build date 06 08 1 the selector shaft has four grooves -A-.

The spring clip -B- is inserted in the cover.

138 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Functional check
. Volkswag
Selector shaft is locked into cover by kinserting
wage
n AGa spring eclip -B-
n AG d
oethrough
s no one of the grooves -A-, with a forward
gear engaged. Vol s t gu
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ed ran
ris tee
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au ac
ss
9 - Dismantling and assembling selector forks

ce
e
nl

pt
du

an
itte

y li
9.1 - Dismantling and assembling selector forks
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Special tools and workshop equipment required

◆ VW 402 Thrust plate

◆ VW 408 A Press tool
◆ VW 431 Press piece
◆ VW 447 H Press plate
◆ VW 472/2 Spacer sleeve
◆ 10-206 Drift

8.1 - Dismantling and assembling gearbox selector mechanism from 10.99 139
 Polo Estate 1998 agen➤
AG. Volkswagen AG d
oes
ksw not
5-speed manual
by Vol
gearbox 02J - Edition gu01.2000
a
ed ran
oris tee
th or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 Selector segment
◆ Identification => Fig. 1
◆ After installing the circlip the selector segment must rotate freely
2 Circlip
◆ Lever off with screwdriver
◆ Installing => Fig. 2
◆ Always renew
3 5th gear selector fork
◆ Adjusting => Page 116
4 5th gear selector jaw
5 Bolt, 25 Nm
6 5th gear selector plate
7 Circlip
8 Washer
9 3rd/4th gear selector plate

140 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
r

10 1st/2nd gear selector plate

o

his
ate

11 Reverse gear selector plate

do
priv

12 3rd/4th gear selector fork cum

for

en
ng

◆ With selector segments => Fig. 5

t.
yi Co
op py
13 Selector segment t. C rig
gh ht
yri by
◆ Identification => Fig. 1 cop Vo
by lksw
◆ After installing the circlip the segment must rotate freely cted agen
Prote AG.
14 Bearing
15 Bearing inner race
◆ Removing => Fig. 3
◆ Pressing in => Fig. 4
16 1st/2nd selector fork
◆ With selector segments => Fig. 5

9.1 - Dismantling and assembling selector forks 141

 AG. Volkswagen AG d
agen oes
olksw not
Polo Estate 1998 ➤ d by
V gu
ara
e nte
5-speed manual gearbox 02J horis
- Edition 01.2000 eo
aut ra
ss c

ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

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es, in part or in w

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rrectness of i
l purpos

nf
ercia

orm
m

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om

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or c

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te

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Prote AG.

17 Selector segment
◆ Identification => Fig. 1
◆ After installing the circlip the segment must rotate freely
18 Circlip
19 Support for reverse gear selector fork
20 Reverse gear selector fork
21 Spring
22 Domed sliding piece

142 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.1 Identifying selector segments

Dimension -a-
AG. Volkswagen AG d
agen oes
lksw not
1- 1st and 2nd gear selector segments = 12.1 by mm
Vo gu
ara
ed
ris nte
o eo
2- 3rd and 4th gear selector segmentsaut= 7.7 mm
h
ra
ss c

ce
le

3 - 5th gear selector segments = 12.1 mm

un

pt
an
d
itte

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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

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Cop py
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Prote AG.

-> Fig.2 Installing circlip

- Press circlip into selector segment groove with socket.

Note:

After installing the circlip the selector segment must rotate freely.

9.1 - Dismantling and assembling selector forks 143

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
A - Socket driver, 10 mm A/F

B - Jaw protectors

AG. Volkswagen AG d
agen oes
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d
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ility
ot

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

-> Fig.3 Removing bearing inner race

m

a
com

tion in
r

Note:
te o

thi
s
iva

do
r

When removing and installing the inner races do not bend selector forks.
rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
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cted agen
Prote AG.

144 34 - Controls, Housing

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.4 Pressing inner race in onto stop

AG. Volkswagen AG d
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d
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ility
ot p

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

-> Fig.5 Selector fork with selector segments installed

thi
te

sd
iva

o
pr

Dim. -a- (mm)

um
r
fo

en
ng

t.
1st/2nd gear selector fork op
yi
87.2 ... 87.9 Co
py
3rd/4th gear selector forks 96.0 ... 96.7
t. C rig
gh ht
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Vo
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Selector segment assignment => Fig. 1 .
cted agen
Prote AG.

9.1 - Dismantling and assembling selector forks 145

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

35 - Gears, Shafts

1 - Dismantling and assembling input shaft

1.1 - Dismantling and assembling input shaft

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ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

Special tools and workshop equipment required

s

◆ VW 407 Press tool

s o

◆ VW 447 H Press plate

cial p

f in

◆ VW 412 Press tool

form
mer

◆ VW 422 Tube
atio

◆ VW 401 Thrust plate

om

◆ VW 408 A Press tool

c

i
or

n thi
te

sd
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cum
r
fo

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t. rig
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Vo
co lksw
by
cted agen
Prote AG.

146 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
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ab

Special tools and workshop equipment required

ility
ot p

wit
, is n

◆ VW 421 Tube
h re
hole

◆ VW 454 Press piece

spec

◆ VW 447 i Thrust plate

es, in part or in w

t to the co

◆ VW 510 Press piece

◆ 41-501 Drift sleeve
rrectness of i
l purpos

nf
ercia

orm
m

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om

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te

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rig ht
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1.1 - Dismantling and assembling input shaft 147

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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Notes:
itte

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ab
ility
ot p

◆ When installing new gears, consult technical data

wit
is n

=>page 2 .
h re

◆ If the position of the taper roller bearings is affected when exchanging parts, the input shaft must be re-
ole,

spec

adjusted. See adjustment overview => Page 220

urposes, in part or in wh

t to the co

1 Clutch housing
2 Taper roller bearing outer race
rrectne

◆ Removing => Fig. 1

◆ Pressing in => Fig. 2
s

3 Taper roller bearing inner race

s o
cial p

◆ Knock-off the input shaft with a drift

inform

◆ Pressing on => fig. 3

mer

4 Input shaft
atio
om

◆ Adjusting => Page 160

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

148 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
lkswage es n
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byV ua
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tho
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ss

ce
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an
d
itte

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rm

ab
pe

ility
ot

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, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tio

5 3rd gear
n in
r
te o

thi

◆ Shoulder points to 4th gear

s
iva

◆ Pressing off => Fig. 5

do
r
rp

◆ Pressing on => Fig. 6

um
fo

en
g

6 Circlip
n

t.
yi Co
op py
◆ Always renew t. C rig
gh ht
yri
7 4th gear
p by
co Vo
by lksw
◆ Pressing off with taper roller bearing outer race and sleeve
cted agen
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=> Fig. 4
◆ Pressing on => Fig. 7
◆ Collar faces to 3rd gear
8 Taper roller bearing inner race
◆ Pressing off with 4th gear wheel and sleeve => Fig. 4
◆ Pressing on => Fig. 8
9 Thrust washer
10 Taper roller bearing outer race
◆ Pressing out => Fig. 10
◆ Pressing in => Fig. 11

1.1 - Dismantling and assembling input shaft 149

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
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11 Shim

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un

pt
◆ Determining thickness => adjusting input shaft, Page 160
an
d
itte

y li
12 Gearbox housing
erm

ab
ility
ot p

13 Sleeve
wit
is n

◆ For needle roller bearing

h re
ole,

◆ Press off with 4th gear wheel and taper roller bearing inner race spec
=> Fig. 4
urposes, in part or in wh

◆ Pressing on => fig. 9

t to the co

◆ Place thrust washer on before installing (item 9)

14 Needle roller bearing
rrectne

15 Selector gear for 5th gear

◆ Pull off together with 5th gear
s

synchro-hub
s o

=>from Page 100

cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

150 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
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cted agen
Prote AG.

16 5th gear synchro-ring

◆ With cast locking pieces =>Fig. 12
◆ Check for wear
=> Page 114
17 Spring
◆ Installation position => Fig. 14
18 Locking pieces (Qty. 3)
◆ Installation position => Fig. 13
19 5th gear synchro-hub
◆ Removing and installing
=> Page 100
20 5th gear locking collar
◆ Removing and installing
=>Page 100

1.1 - Dismantling and assembling input shaft 151

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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tho
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ce
e
nl

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du

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ility
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, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

21 Dished washer
◆ Installation position => Page 116
nf
ercia

22 Torx socket head bolt M 10,

orm

80 Nm
m

atio
m

◆ Fitted piece on bolt head locates dished spring => Page 116
o

n in
or c

thi
te

sd
iva

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rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
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by
cted agen
Prote AG.

152 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

-> Fig.1 Pressing out taper roller bearing outer race

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.1 - Dismantling and assembling input shaft 153

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.2 Pressing in taper roller bearing outer race

n AG. Volkswagen AG do
lkswage es n
o ot g
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d ran
ir se tee
tho
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ss
ce
e
nl

pt
du

an
itte

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erm

ab
ility

-> Fig.3 Pressing on taper roller bearing inner race

ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

154 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.4 Pressing off 4th gear wheel with taper roller bearing and sleeve

AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

-> Fig.5 Pressing off 3rd gear wheel atio

om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.1 - Dismantling and assembling input shaft 155

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.6 Pressing on 3rd gear wheel

n AG. Volkswagen AG do
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o ot g
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ir se tee
tho
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a ac
ss

ce
e
nl

pt
du

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
-> Fig.7 Pressing on 4th gear wheel
l purpos

nf
ercia

Shoulder points to 3rd gear.

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

156 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.8 Pressing on taper roller bearing inner race n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
-> Fig.9 Pressing on sleeve for needle roller bearing
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

-> Fig.10 Pressing out taper roller bearing outer race

1.1 - Dismantling and assembling input shaft 157

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.11 Pressing in taper roller bearing outer race

- Install with shim after adjusting input shaft.

-> Fig.12 5th gear synchro-ring with cast locking pieces (arrows)

AG. Volkswagen AG d
agen oes
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itte

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erm

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ility
ot p

wit
is n

h re

-> Fig.13 5th gear synchronizer

ole,

spec
urposes, in part or in wh

1 - Springs for lock pieces

t to the co

2 - Locking collar
With 3 recesses (arrows A) for the locking pieces (item 4)
3 - Synchro-hub
rrectne

4 - Locking pieces
Installation position: The thin extension (arrow B) faces the pointed teeth of the locking collar (item 2)
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

158 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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tho
u or
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ce
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an
d
itte

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rm

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ility
ot

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, is n

h re
hole

spec
es, in part or in w

-> Fig.14 Assembling 5th gear locking collar/synchro-hub

t to the co
- Push locking collar over synchro-hub.
rrectness of i
Pointed teeth -A- and shoulder -B- of synchro-hub face in same direction. The recesses for the locking pieces
in locking collar and synchro-hub must be aligned (Fig. 13 ).
l purpos

- Insert locking pieces (Installation position: Fig. 13 ).

nform
ercia

- Insert springs offset by 120° underneath lug -C-. The angled ends of the spring must be directly behind the
locking pieces (arrows).
m

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.1 - Dismantling and assembling input shaft 159

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

2 - Adjusting input shaft

2.1 - Adjusting input shaft

AG. Volkswagen AG d
agen oes
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y V gu
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pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

(Determining input shaft adjustment shim)

rrectness of i

Special tools and workshop equipment required

l purpos

◆ VW 387 Universal dial gauge bracket

◆ VW 385/17 End measuring plate
nform

◆ VW 510 Press piece

ercia

◆ VW 447 i Thrust plate

m

◆ VW 407 Press tool

com

tio

◆ V.A.G 1331 Torque wrench

n in
r
te o

◆ Dial gauge
thi
s
iva

do
r
rp

It is only necessary to readjust the input shaft when the following components are renewed:
um
fo

en
ng

t.
yi Co
◆ Gearbox housing Cop py
t. rig
◆ Clutch housing yri
gh by
ht
◆ Input shaft cop Vo
by lksw
◆ 4th gear wheel cted agen
Prote AG.

160 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
or the

◆ Taper roller bearings

Adjustment overview => Page 220

- Press taper roller bearing outer race without shim into gearbox housing onto stop, using VW 510.
- Install input shaft in clutch housing and assemble gearbox housing. Tighten hexagon head bolts to 25 Nm
and then turn 90° further.
- -> Fit measuring appliance and D.T.I. in clutch housing (large taper roller
AG. Vbearing
olkswagenin G
gearbox housing).
- Before taking any measurements, rotate input shaft to allow bearings
swagen to settle. Set A
dialdogauge
es n to "O" with 1
k
mm preload. y Vol ot g
ua
db r e an
ris tee
utho or
a ac
ss

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
161
AG.
2.1 - Adjusting input shaft
 Polo Estate 1998 ➤
. Volkswagen AG
5-speed manual gearbox
swa
gen AG 02J - Edition does01.2000
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Note:
co lksw
by
cted agen
Prote AG.

This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to
the starting position.

- -> Press input shaft in direction of D.T.I. (arrow).

- Read off and note clearance indicated on D.T.I. (example 1.21).

Note:

D.T.I. does not return to original position.

- Determine thickness of shim from table => Page 162 (example 1.175).

- Remove input shaft and press taper roller bearing outer race out of gearbox housing using VW 447i .
- Press taper roller bearing outer race together with the 1.175 shim into gearbox housing using VW 510.
- Assemble gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90° further.

2.2 - Table of adjustment shims

Measured Shim
bearing clearance Thickness (mm) Part No.
(mm)
0.671 ... 0.699 0.650 02A 311 140
0.700 ... 0.724 0.675 02A 311 140 A
0.725 ... 0.749 0.700 02A 311 140 B
0.750 ... 0.744 0.725 02A 311 140 C
0.775 ... 0.799 0.750 02A 311 140 D
0.800 ... 0.824 0.775 02A 311 140 E
0.825 ... 0.849 0.800 02A 311 140 F
0.850 ....0.874 0.825 02A 311 140 G
0.875 ... 0.899 0.850 02A 311 140 H

162 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Measured Shim
0.900 ... 0.924 0.875 02A 311 140 J
0.925 ... 0.949 0.900 02A 311 140 K
AG. Volkswagen AG d
0.950 ... 0.974 0.925 ksw02A
agen311 140 L oes
not
Vol
0.975 ... 0.999 0.950 d by 02A 311 140 M gu
ara
1.000 ... 1.024 rise
0.975 02A 311 140 N nte
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1.025 ... 1.049 s a 1.000
u 02A 311 140 P ra
c
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1.050 ... 1.074 1.025 02A 311 140 Q

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1.075 ... 1.099 1.050 02A 311 140 R
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1.100 ... 1.124 1.075 02A 311 140 S

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1.125 ... 1.149 1.100 02A 311 140 T

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1.150 ... 1.174 1.125 02A 311 140 AA

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1.175 ... 1.199 1.150 02A 311 140 AB

h re
hole

spec
Measured Shim
es, in part or in w

t to the co
bearing clearance Thickness (mm) Part No.
(mm)
1.200 ... 1.224 1.175 02A 311 140 AC

rrectness of i
1.225 ... 1.249 1.200 02A 311 140 AD
l purpos

1.250 ... 1.274 1.225 02A 311 140 AE

1.275 ... 1.229 1.250 02A 311 140 AF
1.300 ... 1.324 1.275 02A 311 140 AG

nf
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1.325 ... 1.349 1.300 02A 311 140

rm
m

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02A 311 140
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c

1.350 ... 1.374 1.325 02A 311 140

or

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02A 311 140 A
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1.375 ... 1.399 1.350 02A 311 140 A

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02A 311 140 A
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1.400 ... 1.424 1.375 02A 311 140 A
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02A 311 140 B t. C rig
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1.425 ... 1.449 1.400 02A 311 140 B cop Vo
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1.450 ... 1.474 1.425 02A 311 140 B
02A 311 140 C
1.475 ... 1.499 1.450 02A 311 140 C
02A 311 140 C
1.500 ... 1.524 1.475 02A 311 140 C
02A 311 140 D

Measured Shim
bearing clearance Thickness (mm) Part No.
(mm)
1.525 ... 1.549 1.500 02A 311 140 D
02A 311 140 D
1.550 ... 1.574 1.525 02A 311 140 D
02A 311 140 E
1.575 ... 1.599 1.550 02A 311 140 E
02A 311 140 E
1.600 ... 1.624 1.575 02A 311 140 E
02A 311 140 F
1.625 ... 1.649 1.600 02A 311 140 F
02A 311 140 F
1.650 ... 1.674 1.625 02A 311 140 F
02A 311 140 G
1.675 ... 1.699 1.650 02A 311 140 G
02A 311 140 G
1.700 ... 1.724 1.675 02A 311 140 G
02A 311 140 H
1.725 ... 1.749 1.700 02A 311 140 H
02A 311 140 H

2.2 - Table of adjustment shims 163

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Measured Shim
1.750 ... 1.774 1.725 02A 311 140 H
02A 311 140 J
1.775 ... 1.791 1.750 02A 311 140 J
02A 311 140 J

2.3 - Performing measurement check

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- -> Install measuring appliance and dial gauge
hole

- Rotate input shaft so that the taper roller bearings settle.

spec
- Press input shaft in direction of arrow.
es, in part or in w

t to the co
- Bearing play should be min. 0.01 ... max. 0.09 mm.

Note:
rrectness of i

If the bearing clearance cannot be measured, but input shaft play is perceptible and the input shaft turns freely,
l purpos

the adjustment is acceptable.

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Prote AG.

164 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

3 - Dismantling and assembling output shaft

3.1 - Dismantling and assembling output shaft

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Special tools and workshop equipment required

spec
urposes, in part or in wh

t to the co

◆ VW 407 Press tool

◆ VW 412 Press tool
◆ VW 512 Press disk
rrectne

◆ V.A.G 1582 Puller

◆ V.A.G 1582/4 Grip piece
◆ V.A.G 1582/5 Grip piece
ss o
cial p

f inform
mer

atio
om

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c

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fo

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t.
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Cop py
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Prote AG.

3.1 - Dismantling and assembling output shaft 165

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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spec
es, in part or in w

t to the co
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Special tools and workshop equipment required

l purpos

◆ VW 402 Thrust plate

◆ 32-111 Thrust piece
nform
ercia

◆ VW 408 A Press tool

◆ VW 407 Press tool
m

◆ VW 457 Support rails

com

tion in

◆ VW 519 Tube
r
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rig ht
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Prote AG.

166 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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Special tools and workshop equipment required

an
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ab

◆ VW 429 Thrust ring

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◆ VW 415 A Tube
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◆ VW 447 H Press plate

h re

◆ VW 454 Press piece

ole,

spec

◆ VW 455 Fitting sleeve

urposes, in part or in wh

◆ 41-501 Drift sleeve

t to the co
rrectness o
cial p

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mer

atio
om

n
c

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fo

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t.
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Cop py
t. rig
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pyri by
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Prote AG.

3.1 - Dismantling and assembling output shaft 167

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Special tools and workshop equipment required

◆ 1 - Internal puller Kukko 21/6

◆ 4 - Kukko 22/2 Counter support

◆ 1 - Two-arm puller Kukko 20/10

With 250 mm long hooks

AG. Volkswagen AG d
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Prote AG.

168 35 - Gears, Shafts

 AG. Volkswagen AG d
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Polo Estate 1998 ➤
a
ss 5-speed manual gearbox c 02J - Edition 01.2000

ce
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nl

pt
Notes:

du

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◆ The output shaft is dismantled as follows:

y li
erm

ab
- Position separating device under 2nd gear wheel (item 19 ) and press off as described in Fig. 5.

ility
- Remove circlip (item 15 ). ot p

wit
, is n

- Position two-arm puller under bearing support (item 9 ) and pull off locking collar with 1st and 2nd gear

h re
synchro-hub as described in Fig. 6 .
hole

spec
◆ When installing new gears or a new output shaft consult technical data
es, in part or in w

=>Page 2 .

t to the co
◆ Both taper roller bearings must be renewed together as a set.

rrectness of i
l purpos

nf
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Prote AG.

1 Hexagon nut, 25 Nm and then turn 90°further

◆ 4 nuts for bearing support
2 Clutch housing
3 Shim
◆ For output shaft
◆ Adjustment overview
=> Page 220
4 Small taper roller bearing outer race
◆ Removing => Fig. 1
◆ Pressing in => Fig. 2
5 Small taper roller bearing inner race
◆ Pulling off => Fig. 3
◆ Pressing on => Fig. 4

3.1 - Dismantling and assembling output shaft 169

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

6 Output shaft
◆ Is paired with final drive gear, always renew together as a set
◆ Adjusting => Page 195

AG. Volkswagen AG d
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7 Large taper roller bearing inner race

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◆ Pulling off => Fig. 7

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◆ Pressing on => Fig. 8

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8 Sealing ring
h re
hole

◆ Place sealing rings (Qty. 4) on the bearing support bolts

spec
es, in part or in w

9 Bearing support
t to the co

◆ With large taper roller bearing outer race and bolts

◆ Only change outer race together with large taper roller bearing and bearing support
rrectness of i

10 Thrust washer
◆ Shoulder on thrust washer faces taper roller bearing
l purpos

11 1st selector gear

nform
mercia

at
om

ion
c

in t
or

his
ate

do
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cum
for

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Cop py
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rig ht
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170 35 - Gears, Shafts

co Vo
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Prote AG.
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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12 Needle roller bearing ss a c
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◆ For 1st gear

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13 1st gear synchro-ring

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◆ Checking for wear

pe

ility

=> Fig. 9
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◆ Identification => Fig. 14

h re

◆ From gearbox build date 04 09 0 the synchronisation for the 1st gear has been modified =>Page 191
hole

spec

14 1st and 2nd gear locking collar with synchro-hub

es, in part or in w

t to the co

◆ Pull off with bearing support after removing the circlip (item 15 )
=> Fig. 6
◆ Dismantling => Fig. 10
rrectness of i

◆ Assembling locking collar/synchro hub => Fig. 10 and Fig. 11

◆ Installation position => Fig. 12
l purpos

◆ Pressing on => Fig. 13

◆ From gearbox build date 04 09 0 the synchronisation for the 1st gear has been modified =>Page 191
nform
mercia

a
com

tion in
r
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s
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Prote AG.

3.1 - Dismantling and assembling output shaft 171

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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d
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ab
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wit
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
a

15 Securing clip
iv

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pr

cum
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16 2nd gear synchro-ring

fo

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ng

t.
yi
◆ Identification => Fig. 14
Co
op py
◆ Checking for wear t. C rig
gh ht
=> Fig. 16 yri
p by
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by c
◆ Assemble so that the recesses locate in the locking collar (item 14 ) locking pieces
lksw
cted agen
Prote AG.
17 Outer ring
◆ Insert in the synchro-ring (item 16 ). Installation position => Fig. 17
◆ Renew if scored
18 Synchro-ring
◆ (Inner ring)
◆ Checking for wear
=> Fig. 18
◆ Check lugs for scoring
◆ Installation position => Fig. 19

172 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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19 2nd gear
an
d
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◆ Installation position => Fig. 20

rm

ab
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ility

20 Needle roller bearing

ot

wit
, is n

◆ For 2nd gear

h re
hole

21 Thrust washer
spec
es, in part or in w

22 Sleeve for 3rd gear needle roller bearing

t to the co

◆ Pressing off with 2nd gear wheel

=> Fig. 5
◆ Pressing on => Fig. 21
rrectness of i

23 Needle roller bearing

l purpos

◆ For 3rd gear

24 Selector gear for 3rd gear
nform
ercia

25 3rd gear synchro-ring

m

◆ Checking for wear

com

tion in

=> Fig. 9
r
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t.
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cted agen
Prote AG.

3.1 - Dismantling and assembling output shaft 173

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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pt
du

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ility
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spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

at

26 Locking collar with 3rd and 4th gear synchro-hub

om

ion
c

◆ Press off with 2nd gear wheel (item 19) and 3rd gear wheel (item 24) => Fig. 5
in t
or

his
e

◆ Dismantling => Fig. 22

at

do
riv

◆ Installation position locking collar/synchro-hub => fig. 24

p

cum
or

◆ Assembling locking collar/synchro-hub => Fig. 22 and Fig. 23

f

en
g

◆ Pressing on => Fig. 25

n

t.
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27 Sleeve t. C rig
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yri
◆ For needle roller bearing p by
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◆ Press off with locking collar and 3rd and 4th gear synchro-hub (item 26) Prote
cted agen
=> Fig. 5
AG.

◆ Pressing on => Fig. 26

28 Needle roller bearing
◆ For 4th gear

174 35 - Gears, Shafts

 n AG. Volkswagen AG do
lkswage es n Polo Estate 1998 ➤
o ot g
byV 5-speed manual gearbox
ua 02J - Edition 01.2000
ed ra
ris nte
tho eo
au ra
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ss

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le
un

pt
an
d
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ab
ility
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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

29 4th gear synchro-ring

◆ Checking for wear
=> Fig. 9
30 Selector gear for 4th gear
31 Thrust washer
32 Needle roller bearing
◆ For output shaft
◆ Removing and installing
=> Page 125
33 Gearbox housing
34 Sleeve
◆ For output shaft needle roller bearing
◆ Pressing off => Fig. 5
◆ Pressing on => Fig. 27
35 5th gear
◆ Removing and installing
=> Page 100

3.1 - Dismantling and assembling output shaft 175

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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36 Dished spring ss a ra
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◆ Installation position => Page 116 ce
le
un

37 Torx socket head bolt M10, 80 Nm pt

an
d
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◆ Fitted portion on bolt head holds saucer spring washer in position
rm

ab
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hole

spec
es, in part or in w

t to the co
rrectness of i
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tion in
r
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Cop py
t. rig
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Prote AG.

176 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
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ab
ility
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hole

spec
es, in part or in w

t to the co
-> Fig.1 Pulling out small taper roller bearing outer race

rrectness of i
A - Internal extractor 37 ... 46 mm, e.g. Kukko 21/6
l purpos

B - Counter support, e.g. Kukko 22/2

nf
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Prote AG.

3.1 - Dismantling and assembling output shaft 177

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.2 Pressing in small taper roller bearing outer race

-> Fig.3 Pulling off small taper roller bearing inner race

A - Vice clamps/vice AG. Volkswagen AG d

agen oes
lksw not
- Fit gripping device and tension behind bearing by V rollers, then turn bearing and
o guretension
ara gripping device.
ed
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es, in part or in w

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rrectness of i
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nform
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a
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tion in
r
te o

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do
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fo

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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

178 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.4 Pressing on small taper roller bearing inner race

-> Fig.5 Pressing off 3rd and 4th gear synchro-hub/locking collar, 2nd, 3rd and 4th gear wheels with output
shaft needle roller bearing sleeve

A - Separating device 22 ... 115 mm, e.g. Kukko 17/2

AG. Volkswagen AG d
agen oes
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B - Hexagon bolt 17 mm AF - M10 x 20 by V ol not
gu
d ara
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Note: ho eo
aut ra
ss c
ce

Support separating appliance so that the 1st and 2nd gear locking collar is not pulled off at the same time.
le
un

pt
an
d
itte

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ility
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wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio

-> Fig.6 Pulling off locking collar with synchro-hub via bearing support
om

n
c

i
or

n thi
te

sd
va

A - Two-arm puller, e.g. Kukko 20/10 with

i

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pr

cum
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250 mm reach hooks

fo

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t.
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Cop py
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rig ht
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Prote AG.

3.1 - Dismantling and assembling output shaft 179

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
B - Hexagon bolt 17 mm AF - M10 x 20 . Volkswagen AG
gen AG
Note: wa does
olks not
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Remove circlip before pullingrisoff
ed individual components.
b ara
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an
d
itte

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erm

ab
ility
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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
ng

t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted
-> Fig.7 Pulling off large taper roller bearing inner race
agen
Prote AG.

A - protective jaws
- Before fitting puller insert a M 10 x 20 hexagon bolt in the output shaft drilling.

180 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.8 Pressing on large taper roller bearing inner race

A - Thrust washer

- Fit thrust washer before pressing on the inner race. The shoulder faces the inner race.

AG. Volkswagen AG d
agen
-> Fig.9 Checking synchro-ring for wear Volksw
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not
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- Press synchro-ring onto the gear cone and measurehor gap "a" with feeler gauge. eo
aut ra
ss c
Gap "a" New dimension Wear limit
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un

pt
an
d

1st gear 1.0 ... 1.7 mm 0.5 mm

itte

3rd gear 1.0 ... 1.7 mm y li

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4th gear 1.0 ... 1.7 mm ility

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rrectness of i
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mercia

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r
te o

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s
iva

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fo

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by c lksw
cted agen
Prote AG.

3.1 - Dismantling and assembling output shaft 181

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.10 Dismantling and assembling 1st and 2nd gear locking collar and synchro-hub

1- Circlip
2- Locking collar
3- Synchro-hub
4- Locking piece

- Slide locking collar over synchro-hub.

AG. Volkswagen AG d
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The wide shoulder of the synchro-hub d by V (arrow A) and the outer splines guof the locking collar (arrow B) face
ara
opposite directions after assembly.
orise Recesses for locking pieces on synchro-hub nte
eo
and locking collar must align.
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182 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.11 Assembling 1st and 2nd gear locking collar/synchro-hub

• Locking collar is pushed over synchro-hub.

- Insert locking pieces and install springs 120° off-set. The angled end of the spring must locate in the hollow
locking piece.

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183
cted agen
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3.1 - Dismantling and assembling output shaft
AG.
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.12 Installation position 1st and 2nd gear locking collar/synchro-hub

The locking collar splines (arrow 1) point to splines for 3rd/4th gear synchro-hub -A-.

The wide shoulder of the synchro-hub (arrow 2) then faces to 1st gear -B-.

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-> Fig.13 Pressing on 1st and 2nd gear locking collar/synchro-hub
ss c

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d
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Note:
rm

ab
pe

ility
ot

Before pressing on, place 1st gear synchro-ring on 1st gear wheel.
wit
, is n

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es, in part or in w

t to the co
rrectness of i
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mercia

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-> Fig.14 Identifying 1st and 2nd gear synchro-rings

fo

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op
◆ 1st gear synchro-ring: 3 ground-down half teeth (arrow)
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ht. rig
◆ 2nd gear synchro-ring: 3 ground down half teeth (arrow) or 2 ground-down half teeth rig ht
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Only the version with 2 ground-down half teeth is available as a spare part for the 2nd gear synchro-ring.
Prote AG.

184 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.15 Distinguishing 1st and 2nd gear synchro-rings

◆ 1st gear synchro-ring - no recesses

◆ 2nd gear synchro-ring - three recesses (arrows)

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t to the co
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-> Fig.16 Checking 2nd gear synchro-ring for wear

nform
ercia

- Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.
m

at
om

ion
c

Gap "a" New dimension Wear limit

in t
or

his
e

2nd gear 1.2 ... 1.8 mm 0.5 mm

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Prote AG.

3.1 - Dismantling and assembling output shaft 185

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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-> Fig.17 Installation position outer-ring s aut ra
c
s

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un

pt
an
d

The lugs (arrows) face to 1st gear -A-

itte

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erm

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urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

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n
c

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fo

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186 35 - Gears, Shafts

 AG. Volkswagen AG d Polo Estate 1998 ➤
agen
Vo lksw 5-speed manualoes
not gearbox 02J - Edition 01.2000
by gu
d ara
e
-> Fig.18 Checking inner
horis
ring for wear nte
eo
aut ra
s c
- Press inner ring onto 2nd selector gear cone and measure gap "a" with a feeler gauge.
s

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nl

pt
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itte
Gap "a" New dimension Wear limit

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erm

ab
2nd gear 0.75 ... 1.25 mm 0.3 mm

ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

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ion
c

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-> Fig.19 Installation position synchro-ring (inner-ring) -A-

The lugs (arrow 1) locate in the recesses (arrow 2) in the synchro-ring -B-.

-> Fig.20 Installation position 2nd gear wheel

The higher shoulder -A- faces to 1st gear -B-. The recesses in the shoulder (arrows) locate with the lugs of the
outer-ring (arrow => Fig. 17 )

3.1 - Dismantling and assembling output shaft 187

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

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es, in part or in w

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nf
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-> Fig.21 Pressing on needle roller bearing sleeve for 3rd gear
m

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-> Fig.22 Dismantling and assembling 3rd and 4th gear locking collar and synchro-hub

1- Spring
2- Locking piece
3- Locking collar

188 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
4- Synchro-hub

- Slide locking collar over synchro-hub.

The recesses for locking pieces in synchro-hub and locking collar must align.

AG. Volkswagen AG d
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nl

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-> Fig.23 Assembling 3rd and 4th gear locking collar/synchro-hub

hole

spec
es, in part or in w

t to the co

The locking collar has been pushed over the synchro-hub.

rrectness of i

- Insert locking pieces and install springs 120° off-set. The angled end of the spring must locate in the hollow
locking piece.
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Prote AG.

3.1 - Dismantling and assembling output shaft 189

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.24 Installation position 3rd and 4th gear locking collar/synchro-hub

Chamfer (arrow) faces to 4th gear.

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190 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.25 Pressing on 3rd and 4th gear synchro-hub with locking collar

-> Fig.26 Pressing on sleeve for 4th gear needle roller bearing

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urposes, in part or in wh

-> Fig.27 Pressing on sleeve for output shaft needle roller bearing

t to the co
rrectne
3.2 - From gearbox build date 04 09 0 the synchronisation for 1st gear has been modified
ss o
cial p

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mer

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Prote AG.

3.1 - Dismantling and assembling output shaft 191

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> The following components have been added or modified:
AG. Volkswagen AG d
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◆ A- Inner ring y Volksw not
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◆ B- Outer ring ise
d b ara
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◆ C- Synchro-ring thor eo
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with additional recesses -4- for the lugs -1- of inner ring -A-.

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◆ 1st gear wheel

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with additional recesses -3- for the lugs -2- of outer ring -B-.

wit
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hole

Note:

spec
es, in part or in w

t to the co
For the 2nd gear the same inner ring, outer ring and synchro ring are installed.

- If the components are not renewed, ensure they are reallocated to the original gear.

rrectness of i
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-> Installation position of inner ring, outer ring and synchro-ring 1st gear:

- Place inner ring -A- on 1st gear wheel.

Angled lugs (arrow 1) point towards outer ring -B-.

- Fit outer ring -B-.

Lugs (arrow 2) engage in gear wheel recesses (arrow 3).

- Fit synchro-ring -C-.

The recesses (arrow 4) engage in lugs (arrow 1) of inner ring -A-.

192 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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d
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ility
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hole

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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
-> Check inner ring 1st gear for wear
r
te o

thi
s
iva

- Press inner ring onto gear wheel cone and measure gap "a" with a feeler gauge.
do
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rp

cum
fo

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Gap "a" New dimension Wear limit

t.
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1st gear 0.75 ... 1.25 mm 0.3 mm
t. C rig
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3.2 - From gearbox build date 04 09 0 the synchronisation for 1st gear has been

modified 193
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Check synchro-ring 1st gear and outer ring for wear

- Press synchro-ring, outer-ring and inner-ring onto selector gear cone and measure gap "a" with feeler gauge.

Gap "a" New dimension Wear limit

1st gear 1.2 ... 1.8 mm 0.5 mm

-> Assembling locking collar and locking pieces with 1st and 2nd gear synchro-hub

1- Circlip
2- Locking collar
3- Synchro-hub
4- Locking piece wage
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With introduction of the modified 1st gear synchronisation
ir se
d the shoulder has the same width ran on both
tee
sides of
synchro-hub. utho
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ss
The shoulder has a chamfer on one side (arrow B).

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After assembly the shoulder of the synchro-hub and the outer splines of the locking collar (arrow A) face same
rm

ab
direction.
pe

ility
ot

wit
, is n

Recesses for locking pieces on synchro-hub and locking collar (arrow C) must align.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
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tion in
r
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-> Installation position of locking collar/synchro-hub 1st and 2nd gear

n

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The locking collar splines (arrow) point to splines for 3rd/4th gear synchro-hub -A-.
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- Remove the 1st gear synchro-hub as described and install again. Prote AG.

194 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

4 - Adjusting output shaft

4.1 - Adjusting output shaft

AG. Volkswagen AG d
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es, in part or in w

t to the co
rrectness of i
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mercia

a
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tion in
r
te o

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Prote AG.

(Determining shim for output shaft)

Special tools and workshop equipment required

◆ VW 387 Universal dial gauge bracket

◆ VW 385/17 End measuring plate
◆ VW 512 Press disk
◆ 3114/2 Straightening tool
◆ VW 407 Press tool
◆ V.A.G 1331 Torque wrench
◆ Dial gauge

4.1 - Adjusting output shaft 195

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Special tools and workshop equipmentenrequired

AG. Volkswagen AG
wag does
olks not
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◆ 1- Internal puller Kukkose21/6
d b ara
nte
◆ 4- Kukko 22/2 Counter tho support
ri eo
au ra
c
ss
It is necessary to readjust the output shaft when the following components are renewed:

ce
e
nl

pt
du

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itte

◆ Final drive

y li
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ab
◆ Clutch housing

ility
ot p

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or

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hole

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◆ Taper roller bearing
es, in part or in w

t to the co
Adjustment overview => Page 220

- Press small taper roller bearing outer race together with a 0.65 mm thick shim fully into clutch housing=>Page rrectness of i
178 .
l purpos

- Insert output shaft and tighten nuts for bearing support to 25 Nm, then turn 90° further.
nform
mercia

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c

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for

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- -> Mount dial gauge (3 mm measuring range) and set to "0" with 1 mm preload.

196 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Move output shaft up and down and note dial gauge reading (example: 0.30 mm).

Determining thickness of shim

The specified bearing preload is obtained by adding

a constant preload figure of (0.20 mm)
to the reading obtained (0.30 mm)
and the thickness of the shim installed (0.65 mm).

Example:

Shim installed 0.65 mm

+ Reading 0.30 mm
+ Preload (constant) 0.20 mm
Thickness of shim 1.15 mm

- Remove output shaft and pull out small taper roller bearing outer race => Page 177

The following adjustment shims are available:

Size (mm) Part No.

0.65 020 311 391 P
0.70 020 311 391 Q
0.75 020 311 391
0.80 020 311 391 A
0.85 020 311 391 B
0.90 020 311 391 C
0.95 020 311 391 D
1.00 020 311 391 E
1.05 020 311 391 F
1.10 020 311 391 G
1.15 020 311 391 H
1.20 020 311 391 J
1.25 020 311 391 K
1.30 020 311 391 L
1.35 020 311 391 M AG. Volkswagen A
1.40 020 311 391
lksw N
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ris to obtain nte
Varying tolerances make it possible
ho the exact shim thickness required.eo
aut ra
ss c
- Press in small taper roller bearing outer race together with the correct shim (in example 1.15 mm) (=>Page
ce
e
nl

178 ) and install output shaft. Tighten bearing support nuts in clutch housing to 25 Nm and then turn 90°
pt
du

an

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197
co Vo
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4.1 - Adjusting output shaft
Prote AG.
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

5 - Dismantling and assembling reverse shaft

5.1 - Dismantling and assembling reverse shaft
AG. Volkswagen AG d
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es, in part or in w

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rrectness of i
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mercia

at
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ion
c

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or

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cum
for

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ng

t.
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Cop py
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Prote AG.

Special tools and workshop equipment required

◆ VW 454 Press piece

◆ VW 447 H Press plate
◆ VW 411 Press tool
◆ 12-551 Centring mandrel
◆ VW 401 Thrust plate
◆ VW 408 A Press tool

198 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

Special tools and workshop equipment required

◆ 1 - Internal puller Kukko 21/2

◆ 4 - Counter support Kukko 22/1

AG. Volkswagen AG d
agen oes
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es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

a
com

tion in
r
te o

thi
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do
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cum
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ng

t.
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Cop py
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Prote AG.

Note:

5.1 - Dismantling and assembling reverse shaft 199

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
After dismantling, always renew needle roller bearing in clutch housing and reverse shaft support.

1 Clutch housing
2 Needle roller bearing
◆ Pulling out => Fig. 1
◆ Pressing in => Fig. 2
3 Reverse gear wheel
4 Circlip
◆ Always renew after removing

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es, in part or in w

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5 Reverse sliding gear wheel cop Vo
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◆ Before replacing remove circlip Prote AG.
◆ Shoulder faces to reverse gear wheel
6 Reverse shaft
◆ Removing => Page 100
7 Needle roller bearing
◆ Pressing out => Fig. 3
◆ Pressing in => Fig.4
8 Reverse shaft support
◆ Removing and installing

200 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
=> Page 100

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pt
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ility
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-> Fig.1 Pulling needle roller bearing out of clutch housing
es, in part or in w

t to the co
A - Counter support, e.g. Kukko 22/1
B - Internal extractor 14.5 ... 18.5 mm, e.g. Kukko 21/2
Note:

rrectness of i
The needle bearing is destroyed during removal and must be renewed.
l purpos

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ercia

orm
m

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Prote AG.

5.1 - Dismantling and assembling reverse shaft 201

 AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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Polo Estate thor 1998 ➤ eo
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5-speedss amanual gearbox 02J - Edition 01.2000 c

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nl

pt
-> Fig.2 Pressing needle roller bearing -A- into clutch housing
du

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es, in part or in w

t to the co
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at
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or

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-> Fig.3 Pressing needle roller bearing out of the reverse shaft support

-> Fig.4 Pressing needle roller bearing into reverse shaft support

202 35 - Gears, Shafts

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

39 - Final drive, Differential rear

1 - Renewing flanged shaft oil seals (gearbox installed)

1.1 - Renewing flanged shaft oil seals (gearbox installed)

AG. Volkswagen AG d
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- Observe general repair instructions ed b ara
nte
is
=> Page 7 . hor eo
aut ra
ss c
Special tools and workshop equipment required

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un

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an
d
itte

◆ VW 771 Multi-purpose tool

y li
erm

ab
◆ VW 771/37 Puller hooks

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
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atio
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n
c

◆ 3106 Drift
or

n thi
te

sd
iva

Special tools and workshop equipment required

pr

cum
r
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.1 - Renewing flanged shaft oil seals (gearbox installed) 203

 AG. Volkswagen
Polo Estate 1998 ➤agen
ksw
AG do
es n
Vol ot g
5-speed manual
db
y gearbox 02J - Edition 01.2000ua
ra
e nte
ris
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◆ V.A.G 1331 Torque
au
t wrench ra
ss c

ce
Removing e
nl

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erm

◆ Before replacing left-hand oil seal:

ab
ility
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wit
- Remove drive shaft
, is n

h re
hole

spec
=> Running gear, axles, steering; Repair group 40; Servicing drive shafts, Removing and installing drive shafts
es, in part or in w

Servicing drive shafts, Removing and installing drive shafts

t to the co
◆ Before replacing right-hand oil seal:

rrectness of i
- Turn steering to right onto full lock stop.
l purpos

- Remove drive shaft protective cap from engine, if fitted.

- Disconnect drive shaft from flanged shaft.
- Tie-up drive shaft as high as possible. Do not damage paint on drive shaft.

nf
ercia

orm
m

atio
om

n in
or c

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te

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rp

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Prote AG.

- Place drip tray underneath.

- -> Remove flange shaft cone head bolt.
- Remove flanged shaft with spring.

204 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

- -> Pull out seal.

Notes:

◆ Do not damage sleeve, otherwise leaks will occur.

◆ Replace sleeve if damaged
=> Page 127 .
AG. Volkswagen AG d
agen oes
Installing olksw not
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es, in part or in w

t to the co
rrectness of i

- -> Drive seal into sleeve onto stop, when doing this do not cant seal.
l purpos

- Fill space between sealing lip and dust lip with grease G 052 128 A1.
- Insert flanged shaft.
- Install cone head bolt into flange shaft threaded piece.
nform
ercia

- Install left-hand drive shaft or attach right-hand drive shaft to flange shaft.
m

a
com

tio

=> Running gear, axles, steering; Repair group 40; Servicing drive shafts, Removing and installing drive shafts
n in
r

Servicing drive shafts, Removing and installing drive shafts

te o

thi
s
iva

do
r

- Install drive shaft protective cover if necessary.

rp

cum
fo

- Top up gearbox oil => Page 88 .

en
ng

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Cop py
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Prote AG.

1.1 - Renewing flanged shaft oil seals (gearbox installed) 205

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
Tightening torques

Flange shaft to gearbox (cone head bolt) 25 Nm

Drive shaft protective cover to engine 35 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
2 - Dismantling and assembling differential ris nte
ho eo
aut ra
ss c
2.1 - Dismantling and assembling differential

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itte

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rm

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pe

ility
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es, in part or in w

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nform
mercia

a
com

tion in
r
te o

thi
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iva

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cum
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en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Special tools and workshop equipment required

◆ V.A.G 1582 Puller

◆ V.A.G 1582/3 Grip
◆ VW 412 Press tool
◆ 40-105 Thrust plate
◆ VW 401 Thrust plate
◆ VW 402 Thrust plate

206 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Special tools and workshop equipment required
ce
e
nl

pt
du

an
itte

y li

◆ VW 408 A Press tool

erm

ab

◆ VW 473 Thrust piece

ility
ot p

◆ 30-205 Thrust plate

wit
, is n

◆ 3144 Sleeve
h re
hole

◆ 2007 Thrust pad

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

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or

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ate

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priv

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for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.1 - Dismantling and assembling differential 207

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

n AG. Volkswagen AG do
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ot

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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

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cum
fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Notes:

◆ Heat taper roller bearing inner race to

100 °C before installing.
◆ Always renew both taper roller bearings together as a set.
◆ If differential housing, gearbox housing or clutch housing taper roller bearings are renewed adjust differential
=> Page 221 .

1 Gearbox housing
2 Bolt
3 Differential cage
◆ Bolt to final drive gear

208 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
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4 Final drive gear wheel

rrectne
◆ Rivetted in production
◆ Is paired with output shaft, only renew as a set s
◆ Pressing off => Fig. 9
s o
cial p

◆ Installation position => Fig. 10

f in

◆ Heat to 100 °C before installing

form
mer

◆ Fit to differential housing

atio
m

=> Fig. 11
o

n
c

◆ Bolted => Fig. 12

i
or

n thi
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5 Backing plate
t

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6 Nut, 70 Nm
p

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fo

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7 Shim
ng

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◆ For differential C py
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◆ Determining thickness => page 221 rig ht
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8 Taper roller bearing outer race by c lksw
cted agen
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◆ Driving out => Fig. 5
AG.

◆ Pressing in => Fig. 6

2.1 - Dismantling and assembling differential 209

 Polo Estate 1998 ➤
5-speed manual gearbox 02J
wage
n- AEdition
G. Volkswa01.2000
gen AG
doe
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Vol t gu
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Cop py
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pyri by
Vo
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Prote AG.

9 Taper roller bearing inner race

◆ Pulling off => Fig. 3
◆ Pressing on => Fig. 4
10 Differential housing
◆ With rivetted final drive gear
◆ When renewing final drive gear drill out rivet heads => Fig. 8
◆ Attaching final drive gear with bolts
=> Fig. 12
11 Speedometer drive wheel
◆ Fit onto differential housing as far as stop before pressing on inner race
12 Taper roller bearing inner race
◆ Pulling off => Fig. 3
◆ Pressing on => Fig. 4

210 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
e
nl

pt
du

an
itte

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ab
ility
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es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

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13 Taper roller bearing outer race Cop py
t. rig
gh
◆ Knocking out => Fig. 1
ht
pyri by
Vo
◆ Pressing in => Fig. 2
o
by c lksw
cted agen
Prote
14 Clutch housing
AG.

15 Sleeve
◆ Installed in conjunction with springs behind flange shafts
◆ To accept oil seal (item 16 )
◆ Removing and installing
=> Page 127
16 Oil seal
◆ Renewing => Page 203
17 Counter-sunk head bolt, 25 Nm
◆ Bolt into threaded piece (item 25 )

2.1 - Dismantling and assembling differential 211

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
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nl

pt
du

18 Flange shaft
an
itte

y li

◆ Removing and installing

erm

ab

=> Page 203

ility
ot p

wit

19 Spring for flanged shaft

, is n

h re

◆ Installed behind flanged shafts

hole

spec

20 Thrust washer
es, in part or in w

t to the co

◆ Installation position:
Shoulder towards spring, tongue to tapered ring
21 Tapered ring
rrectness of i

◆ With grooves to secure thrust washer

l purpos

◆ Installation position: Taper towards differential housing

22 Securing clip
nform
ercia

◆ Ensures taper ring, thrust washer and spring are held in position when flange shaft is removed
m

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Cop py
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rig ht
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Prote AG.

212 39 - Final drive, Differential rear

 AG. Volkswagen AG d
agen oes
olksw no
d by
V
Polo t Estate
gu
ara 1998 ➤
e nte
th5-speed
oris
manual gearbox 02J - Edition e 01.2000
or
au ac
ss

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

23 One-piece thrust washer

◆ Coat with gearbox oil when installing
24 Sun wheel
◆ Installing => Fig. 14
25 Threaded piece
◆ Installing => Fig. 14
26 Planet pinion axis shaft
◆ Knock out with drift
◆ Installing => Fig. 14
27 Spring pin
◆ For securing planet pinion axis shaft
◆ Removing and installing => Fig. 13
28 Planet pinion
◆ Installing => Fig. 14
29 Sun wheel
◆ Installing => Fig. 14

2.1 - Dismantling and assembling differential 213

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness
-> Fig.1 Knocking taper roller bearing outer race out of clutch housing

o
cial p

f inform
mer

- First remove flange shaft seal mounting sleeve on gearboxes with springs behind flange shaft.
atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

214 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.2 Pressing taper roller bearing outer race into clutch housing
No shim is installed in the clutch housing end.

n AG. Volkswagen AG do
lkswage es n
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-> Fig.3 Pulling off taper roller bearing
auth inner race or
ac
ss
- Before fitting the extractor position press piece 40-105 on differential housing.

ce
le
un

pt
an
d

Note:
itte

y li
rm

ab
Both both taper roller bearing inner races are pulled off the differential housing in the same way.
pe

ility
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, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
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tion in
r
te o

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s
iva

do
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fo

en
ng

t.
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

2.1 - Dismantling and assembling differential 215

 AG. Volkswagen AG d
agen oes
olksw not
Polo Estate d by V 1998 ➤ gu
ara
e
5-speedhoris manual gearbox 02J - Edition 01.2000
nte
eo
aut ra
s c
-> Fig.4 sPressing on taper roller bearing inner race

ce
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un

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an
d
itte

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erm

Note:

ab
ility
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The taper roller bearing inner races for gearbox housing and clutch housing are pressed on with the same press
is n

h re
tools.
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
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fo

en
ng

t.
-> Fig.5 Pulling taper roller bearing outer race out of gearbox housing
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
A - Counter support, e.g. Kukko 22/2 Prote
cted AG.
agen

B - Internal puller 46...58 mm, e.g. Kukko 21/7

-> Fig.6 Pressing taper roller bearing outer race into gearbox housing

- Fit shim under outer race.

- Support gearbox housing with sleeve 3144 directly below bearing mounting.

216 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
-> Fig.7 Both sides of differential housing are chamfered (arrow) to accept tapered rings/springs

AG. Volkswagen AG d
agen oes
olksw not
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ility
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, is n

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es, in part or in w

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rrectness of i
l purpos

nform
mercia

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tion in
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te o

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s
iva

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r
rp

cum
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en
ng

-> Fig.8 Drilling out rivet heads

t.
yi Co
Cop py
t. rig
gh
- Drill out rivet heads with 12 mm drill from countersunk side
ht
pyri by
Vo
o
and knock-out with drift.
c by lksw
cted agen
Prote AG.

Note:

Clean differential before and after drilling, protect taper roller bearing from drillings.

-> Fig.9 Pressing off final drive gear

- Place thrust piece 40-105 on differential housing.

2.1 - Dismantling and assembling differential 217

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

AG. Volkswagen AG d
agen oes
olksw not
V
-> Fig.10 Installation position of finaled bydrive gear wheel gu
ara
ris nte
ho eo
aut ra
ss c
The circular groove -A- faces towards bolt-on side of differential.

ce
le
un

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an
d
itte

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erm

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ility
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wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

-> Fig.11 Heating final drive gear wheel to approx. 100 °C and installing
atio
om

n
c

i
or

- Use bolts -A- from repair kit to guide final drive gear into position during installation.
thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

-> Fig.12 Bolting final drive gear and differential housing together

Use special bolts with plates and nuts according to parts catalogue.

218 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

-> Fig.13 Removing and installing planet wheel axis shaft spring pin

Removing

- Cover taper roller bearing inner race and speedometer drive gear to avoid possible damage and ingress of
metal particles.
- Knock-out spring pin with chisel, inserting chisel into circumferential groove.

Installing n AG. Volkswagen AG do

lkswage es n
Vo ot g
- Knock fully into the differential
d by cage. ua
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ility
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es, in part or in w

t to the co
rrectness of i
l purpos

-> Fig.14 Installing sun wheels and planet pinions

nform
ercia

- Lubricate one piece thrust washer with gearbox oil and install.
- Install both sun wheels and secure (e.g. with flanged shaft).
m

at
om

- Insert planet wheels (180°apart) and pivot into position.

ion
c

- Push planet wheel axis shaft (arrow -A-) in until first planet wheel.
in t
or

his
e

- Position threaded pieces (arrow -B-) in sun wheels

at

do
riv

Installation position: step towards sun wheel

p

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co

219
by lksw
cted agen
Prote AG. 2.1 - Dismantling and assembling differential
 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000
- Drive planet wheel axis shaft into final position and secure with spring pin.

3 - Adjustment overview
3.1 - Adjustment overview

Note:

If repairs have been carried out to the gearbox it is only necessary to adjust the input shaft, output shaft or
differential if components have been renewed which have a direct effect on the adjustment of the gearbox.
Refer to the following table to avoid unnecessary adjustment:

to be adjusted:
Input shaft Output shaft Differential
=> Page 160 => Page 195 => Page 221
Parts renewed: Gearbox housing x x
Clutch housing x x x
Input shaft ks
x
n AG. Vol wagen AG do
Output shaft (final drive) olkswage es n
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Differential housing ised b uaran x
r tee
tho
Input shaft taperauroller bearing x or
s ac
Output shaft taper roller bearing
s x

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Differential taper roller bearing x

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4th gear wheel x
erm

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urposes, in part or in wh

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mer

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rig ht
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by lksw
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Prote AG.

220 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox 02J - Edition 01.2000

4 - Adjusting differential
4.1 - Adjusting differential

AG. Volkswagen AG d
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es, in part or in w

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atio
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Special tools, testers and auxiliary items

o

n in
or c

thi
e

◆ VW 387 Universal dial gauge bracket

t

sd
iva

◆ VW 385/17 End measuring plate

o
r
rp

cu

◆ 30-205 Thrust plate

o

m
f

en
ng

◆ VW 407 Press tool

t.
yi Co
op
◆ Dial gauge C py
t. rig
gh ht
pyri by
The differential must be adjusted, when
co Vo
by lksw
cted agen
Prote AG.
◆ Gearbox housing
◆ Clutch housing
◆ Differential housing

or the

◆ Differential taper roller bearing

4.1 - Adjusting differential 221

 AG. Volkswagen AG d
Polo Estate 1998 ➤ ksw
agen oes
not
Vol
5-speed manual gearbox 02J - Editiond b01.2000
y gu
ara
e nte
ris
ho eo
have been renewed. au
t ra
ss c

ce
le
Adjustment overview => Page 220 .

un

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an
d
itte

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rm
- Press taper roller bearing outer race into clutch housing using thrust plate 30-205 => Page 215 .

ab
pe

ility
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Note:

, is n

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hole

spec
Taper roller bearing inner and outer races are paired. Do not interchange!

es, in part or in w

t to the co
- Pressing taper roller bearing outer race without shim into the gearbox housing using thrust piece 30-205 =>
Page 216 .
- Fit differential into clutch housing

rrectness of i
- Fit gearbox housing and tighten 5 bolts to 25 Nm.
l purpos

nform
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- -> Mount dial gauge and "0" with 1 mm preload.

- Move differential up and down and recall play indicated on dial gauge
(Example: 0.70 mm)

Determining shim thickness

The specified bearing preload is obtained by adding a constant figure (0.40 mm) to the reading obtained.

Example:

Reading 0.70 mm
+ Preload (constant figure) 0.40 mm
Thickness of shim = 1.10 mm

- Remove gearbox housing and pull taper roller bearing outer race out from gearbox housing => Page
216 .
- Insert shims of correct thickness, thickest shim first.

The following shims are available:

222 39 - Final drive, Differential rear

 Polo Estate 1998 ➤
5-speed manual gearbox
agen AG 02J
.Volksw-agEdition
en AG
do 01.2000 w es n
olks ot g
yV ua
Size (mm) Part No. ed
b ran
ris tee
0.65 02A 409 210 tho or
au ac
0.70 02A 409 210 A ss

ce
0.75 02A 409 210 B

e
nl

pt
du

an
0.80 02A 409 210 C

itte

y li
0.85 02A 409 210 D

erm

ab
ility
0.90 02A 409 210 E

ot p

wit
0.95 02A 409 210 F

, is n

h re
1.05 02A 409 210 G

hole

spec
1.05 02A 409 210 H

es, in part or in w
1.10 02A 409 210 J

t to the co
1.15 02A 409 210 K
1.20 02A 409 210 L

rrectness of i
1.25 02A 409 210 M
l purpos
If the size of shim required is larger than that listed in the table, insert two shims totalling the correct figure.

nf
ercia

Varying tolerances make it possible by measuring the shims to obtain the exact shim thickness required.

orm
m

atio
m

- Knock-in outer race again and tighten gearbox housing.

o

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by lksw
cted agen
Prote AG.

4.1 - Adjusting differential 223