6-speed manual gearbox 0A2 — Repairing clutch release mechanism — VW
6-speed manual gearbox 0A2 — Repairing clutch release mechanism on VW: 19 steps, 2 torque figures. What to remove, what to tighten and to how many Nm.
Workshop procedure for VW — the exact step sequence and torque figures, straight from real workshop data.
🧭 Before you start
Fits: VW Passat B5 (3B)
- Renewed: o-ring in gearbox housing
Don't miss
- Before installing clutch release lever, thinly coat recess for slave cylinder plunger with copper greaseZ 381 351 TE.
- Before installing bearing, glue loose plastic ring to bearing race using adhesiveAMV 195 KD1 01.
- Moisten new O-ring with gear oil before installing.
🔩 Torque settings
Values can differ between engine variants — check the code stamped on your block.
| Torque | Fastener / step |
|---|---|
| 25 Nm (18 lb-ft) | Insert leaf spring (2) and tighten new bolt (1) |
| 25 Nm (18 lb-ft) | Install locking plate (1) with new bolts (arrows) and tighten bolts |
ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.
📋 Procedure
- Loosen bolt (1) and remove leaf spring (2).
- Remove clutch release lever (3) together with release bearing.
- Disengage release bearing retainer lugs from release lever.
- Before installing clutch release lever, thinly coat recess for slave cylinder plunger with copper greaseZ 381 351 TE.
- Set clutch release lever (3) with release bearing on guide sleeve.
- Insert leaf spring (2) and tighten new bolt (1) to 25 Nm. — 25 Nm (18 lb-ft)
- Before installing bearing, glue loose plastic ring to bearing race using adhesiveAMV 195 KD1 01.
- Remove bolts (arrows) and remove locking plate (1).
- Pull guide sleeve (2) out of gearbox housing.
- Renew O-ring in gearbox housing .
- Fit a thin protective hose tightly over splines of input shaft.
- Half-fill space between sealing lip and dust lip with greaseG 052 128 A1.
- Moisten outer circumference of guide sleeve with gear oil.
- Push guide sleeve (2) over input shaft into gearbox housing.
- Install locking plate (1) with new bolts (arrows) and tighten bolts to 25 Nm. — 25 Nm (18 lb-ft)
- Lever out O-ring (arrow) with a small screwdriver.
- Moisten new O-ring with gear oil before installing.
- Moisten outer circumference of seal with gear oil.
- Press output shaft seal in to stop.
Other VW procedures
- Removing engine · 41 torque figures
- Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
- Adjusting valve timing – VW Passat B5 · 83 torque figures
- Removing and installing camshafts – VW Passat B6 · 39 torque figures
- Removing and installing coolant pump · 53 torque figures
- Removing and installing clutch pedal, Golf Plus
- Connecting battery on right in luggage compartment · 2 torque figures
- Removing and installing fuel tank - Jetta from MY 2011
- Install cylinder head · 1 torque figures
- Dismantling and assembling power assisted steering box (TRW)
Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.