Renewing deep groove ball bearing with gearbox removed but not dismantled — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

Don't miss

• If necessary, pull input shaft by hand out of gearbox housing to stop in order to install retaining ring properly.
• Moisten new O-ring (arrow) with gear oil before installing in circumferential groove of gearbox housing.
• Clean thread of bolts (arrows) with wire brush. Bolts must then be inserted with locking fluidAMV 185 101 A1 and tightened to 24 Nm torque.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

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

1. Loosen bolt (1) and remove leaf spring (2).
2. Remove clutch release lever (3) together with release bearing.
3. Remove bolts (arrows) and remove locking plate (1).
4. Fit a thin protective hose or shrink tube over splines of input shaft.
5. Pull guide sleeve (2) out of gearbox housing.

6. Remove intermediate piece (3) from gearbox housing.
7. Lever out O-ring (arrow) with a small screwdriver.
8. Then remove retaining ring (arrow) in front of deep groove ball bearing of input shaft.
9. Pull deep groove ball bearing for input shaft out of gearbox housing.
10. Then push new deep groove ball bearing onto input shaft.
11. Drive deep groove ball bearing into gearbox housing to stop.
12. Then install retaining ring (arrow) in front of deep groove ball bearing of input shaft. [Note: If necessary, pull input shaft by hand out of gearbox housing to stop in order to install retaining ring properly.]
13. Moisten new O-ring (arrow) with gear oil before installing in circumferential groove of gearbox housing.
14. Half-fill space between sealing lip and dust lip of seal in guide sleeve with sealing greaseG 052 128 A1.
15. Lightly oil outer circumference of guide sleeve.
16. Push guide sleeve (2) over input shaft into gearbox housing.
17. Remove shrink tube or insulation tube.
18. Fit locking plate (1).
19. Clean thread of bolts (arrows) with wire brush. Bolts must then be inserted with locking fluidAMV 185 101 A1 and tightened to 24 Nm torque. — 24 Nm (18 lb-ft)
20. Insert intermediate piece (3) in gearbox housing.
21. Install clutch release lever with release bearing.
22. Apply a thin coat of copper paste to surface of plunger of slave cylinder where it contacts clutch release lever (3).
23. Clean thread of bolt (1) with a wire brush.
24. Set leaf spring (2) on bolt (1).
25. Then insert bolt (1) with locking fluidAMV 185 101 A1 and tighten to 24 Nm torque. — 24 Nm (18 lb-ft)

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