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How to change clutch kit on VW Polo II Hatchback (86C, 80) – replacement guide

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Recommended replacement interval for the part category Clutch kit : 100000 km

Important!

This replacement procedure can be used for:
VW Polo Hatchback (86C, 80) 1.0, VW Polo Hatchback (86C, 80) 1.3 D, VW Polo Hatchback (86C, 80) 1.4 D, VW Polo Hatchback (86C, 80) 1.3 Cat, VW Polo Hatchback (86C, 80) 1.0 Cat, VW Polo Hatchback (86C, 80) 1.3, VW Polo Hatchback (86C, 80) 1.0, VW Polo Hatchback (86C, 80) 1.3 … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Clutch Kit for Polo Hatchback (86C, 80) and other VW models

Alternative products

Clutch kit

Replacement: clutch kit – VW POLO (86C, 80). Tools you might need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Electronic spray
                    
                      All-purpose cleaning spray
                    
                      Brake cleaner 
                    
                      Multipurpose grease
                    
                      Copper grease 
                    
                      Torque wrench
                    
                      Combination spanner #13
                    
                      Combination spanner #16
                    
                      Drive socket # 10 
                    
                      Drive socket # 13 
                    
                      Drive socket # 16 
                    
                      Drive socket # 18 
                    
                      Drive socket # 30 
                    
                      12-point socket # 9
                    
                      XZN socket bit # 8
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Flat screwdriver
                    
                      Pin punch
                    
                      Tap wrench
                    
                      Crow bar
                    
                      Clutch tool kit
                    
                      Engine support beam
                    
                      Hydraulic transmission jack
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: clutch kit – VW POLO (86C, 80). Tip from AUTODOC:

Replace the entire clutch kit assembly: the pressure plate, clutch disc, and release bearing.
Please note: all work on the car – VW POLO (86C, 80) – should be done with the engine switched off.

Carry out replacement in the following order:

Step 1

Open the bonnet.

Step 2

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 3

Unscrew the fasteners of the car battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 4

Remove the battery terminals.
Step 5

Unscrew the battery fastener. Use a drive socket #13. Use a ratchet wrench.
Step 6

Remove the battery.
Step 7

Unscrew the fasteners of the battery tray. Use a drive socket #10. Use a ratchet wrench.
Step 8

Remove the battery tray.
Step 9

Disconnect the clutch cable.
Step 10

Disconnect the engine wiring harness connector.
Step 11

Detach the engine wiring harness.
Step 12

Unscrew the ground wire fastener. Use a combination spanner #13.
Step 13

Disconnect the ground wire.
Step 14

Unscrew the engine starter fasteners. Use a drive socket #13. Use a ratchet wrench.
Step 15

Unscrew the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a ratchet wrench.
Step 16

Secure the wheels with chocks.

Step 17

Loosen the fastener of the driveshaft. Use a drive socket #30. Use a tap wrench.
Step 18

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 19

Raise the front of the car and secure on supports.

Step 20

Unscrew the wheel bolts.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. VW POLO (86C, 80)
Step 21

Remove the wheel.
Step 22

Unscrew the fastener connecting the drive shaft to the wheel hub. Use a drive socket #30. Use a ratchet wrench.
Step 23

Remove the fastening nut.

Step 24

Disconnect the transmission sensor connector.
Step 25

Clean the fasteners connecting the ball joint to the suspension control arm. Use a wire brush. Use WD-40 spray.
Step 26

Unscrew the fastener connecting the ball joint to the suspension control arm. Use a drive socket #13. Use a ratchet wrench.
Step 27

Disconnect the ball joint from the control arm.
Step 28

Detach the driveshaft from the steering knuckle.

Replacement: clutch kit – VW POLO (86C, 80). Tip:
Make sure that the drive shaft is not unloaded (when the car is jacked).
Step 29

Unscrew the fasteners of the CV axle inner joint. Use XZN #8. Use a ratchet wrench.
Step 30

Remove the drive shaft.
Step 31

Secure the engine. Use an engine support beam.
Step 32

Unscrew the fastener of the cable bracket. Use a combination spanner #16.
Step 33

Unscrew the gear shift cable fastener. Use a drive socket #13. Use a ratchet wrench.
Step 34

Remove the gear shift cable retaining clip. Use a flat screwdriver.
Step 35

Clean the gearbox mount fasteners. Use a wire brush. Use WD-40 spray.
Step 36

Unscrew the fasteners that connect the bottom gearbox mount to the gearbox. Use a combination spanner #16.
Step 37

Clean the gearbox mount fasteners. Use a wire brush. Use WD-40 spray.
Step 38

Unscrew the fasteners that connect the gearbox mount to the subframe. Use a drive socket #13. Use a ratchet wrench.
Step 39

Remove the gearbox mount.
Step 40

Support the gearbox. Use a hydraulic transmission jack.

Replacement: clutch kit – VW POLO (86C, 80). AUTODOC experts recommend:
Take care to prevent the gearbox from being unsupported (hanging).
Step 41

Clean the gearbox mount fasteners. Use a wire brush. Use WD-40 spray.
Step 42

Unscrew the gearbox mount fasteners. Use a drive socket #18. Use a ratchet wrench.
Step 43

Unscrew the fastener that connects the gearbox mount to the car body. Use a drive socket #13. Use a ratchet wrench.
Step 44

Remove the gearbox mount.
Step 45

Unscrew the fasteners that connect the bottom gearbox mount to the gearbox. Use a combination spanner #16.
Step 46

Remove the bottom gearbox mount.
Step 47

Unscrew the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a ratchet wrench.
Step 48

Move the gearbox aside.

Replacement: clutch kit – VW POLO (86C, 80). Tip from AUTODOC:
Make sure the gearbox is reliably secured.
Step 49

Remove the support from under the gearbox.

AUTODOC recommends:
Replacement: clutch kit – VW POLO (86C, 80). Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 50

Remove the gearbox.
Step 51

Remove the release bearing. Use a crowbar.
Step 52

Unscrew the pressure plate fasteners. Use 12-point socket No.9. Use a ratchet wrench.
Step 53

Remove the pressure plate together with the clutch disc. Use a crowbar.
Step 54

Clean the clutch kit mounting seats. Use all-purpose cleaning spray.
Step 55

Install the new pressure plate together with the clutch disc.
Step 56

Screw in the pressure plate fasteners. Use 12-point socket No.9. Use a ratchet wrench.
Step 57

Align the clutch disc. Use a crowbar.

Replacement: clutch kit – VW POLO (86C, 80). AUTODOC recommends:
Be careful not to damage the part.
Step 58

Screw in the pressure plate fasteners. Use 12-point socket No.9. Use a ratchet wrench.
Step 59

Install the engine flywheel locking tool. Use a clutch tool kit.
Step 60

Tighten the pressure plate fasteners. Use 12-point socket No.9. Use a torque wrench. Tighten it to 27 Nm torque.
Step 61

Remove the flywheel locking tool.
Step 62

Treat the release bearing mounting seat. Use a multipurpose grease.
Step 63

Install the new release bearing.
Step 64

Support the gearbox. Use a hydraulic transmission jack.
Step 65

Install the gearbox.

Replacement: clutch kit – VW POLO (86C, 80). Tip from AUTODOC:
Take care to prevent the gearbox from being unsupported (hanging).
Step 66

Refit the gearbox to its mounting seat.

Step 67

Screw in the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a ratchet wrench.
Step 68

Tighten the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a torque wrench. Tighten it to 64 Nm torque.
Step 69

Install the lower gearbox mount.
Step 70

Screw in the fasteners that connect the gearbox mount to the gearbox. Use a combination spanner #16.

Step 71

Tighten the fasteners that connect the gearbox mount to the gearbox. Use a combination spanner #16. Use a torque wrench. Tighten it to 64 Nm torque.

Step 72

Install the gearbox mount.
Step 73

Screw in the fasteners that connect the gearbox mount to the car body. Use a drive socket #18. Use a ratchet wrench.
Step 74

Tighten the fasteners that connect the gearbox mount to the car body. Use a drive socket #13. Use a torque wrench. Tighten it to 38 Nm torque.
Step 75

Tighten the fasteners that connect the gearbox mount to the gearbox. Use a drive socket #18. Use a torque wrench. Tighten it to 69 Nm torque.
Step 76

Remove the support from under the gearbox.

AUTODOC recommends:
Replacement: clutch kit – VW POLO (86C, 80). Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 77

Install the gearbox mount.
Step 78

Screw in the fasteners that connect the gearbox mount to the subframe. Use a drive socket #13. Use a ratchet wrench.
Step 79

Tighten the fasteners that connect the gearbox mount to the subframe. Use a drive socket #13. Use a torque wrench. Tighten it to 49 Nm torque.
Step 80

Tighten the fasteners that connect the gearbox mount to the gearbox. Use a combination spanner #16. Use a drive socket #16. Use a torque wrench. Tighten it to 75 Nm torque.
Step 81

Tighten the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a torque wrench. Tighten it to 64 Nm torque.
Step 82

Attach the gear shift cable retaining clip.
Step 83

Screw in the gear shift cable fastener. Use a drive socket #13. Use a ratchet wrench.

Step 84

Screw in the fastener of the cable bracket. Use a drive socket #16. Use a ratchet wrench.
Step 85

Tighten the fastener of the cable bracket. Use a drive socket #16. Use a torque wrench. Tighten it to 22 Nm torque.
Step 86

Clean the CV joint mounting seat. Use all-purpose cleaning spray.
Step 87

Install the drive shaft.
Step 88

Screw in the fasteners of the CV axle inner joint. Use XZN #8. Use a ratchet wrench.
Step 89

Clean the splines of the drive shaft CV joint. Use a wire brush. Use WD-40 spray.
Step 90

Install the steering knuckle on the CV axle.
Step 91

Attach the ball joint to the control arm. Use a pin punch.
Step 92

Screw in the fastener connecting the ball joint to the control arm. Use a drive socket #13. Use a ratchet wrench.
Step 93

Tighten the fasteners of the CV axle inner joint. Use XZN #8. Use a torque wrench. Tighten it to 42 Nm torque.
Step 94

Install the fastening nut.
Step 95

Screw in the nut of the CV axle. Use a drive socket #30. Use a ratchet wrench.
Step 96

Tighten the fasteners connecting the ball joint to the control arm. Use a drive socket #13. Use a torque wrench. Tighten it to 55 Nm torque.
Step 97

Attach the transmission sensor connector.
Step 98

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 99

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: clutch kit – VW POLO (86C, 80). After applying the spray, wait a few minutes.
Step 100

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. VW POLO (86C, 80)
Step 101

Screw in the wheel bolts. Use wheel impact socket #17.
Step 102

Lower the car.

Step 103

Tighten the drive shaft nut. Use a drive socket #30. Use a torque wrench. Tighten it to 175 Nm torque.
Step 104

Tighten the wheel bolts using a criss-cross pattern. Use wheel impact socket #17. Use a torque wrench. Tighten it to 120 Nm torque.
Step 105

Remove the jacks and chocks.

Step 106

Remove the engine support beam.
Step 107

Tighten the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a torque wrench. Tighten it to 64 Nm torque.
Step 108

Tighten the engine starter fasteners. Use a drive socket #13. Use a torque wrench. Tighten it to 29 Nm torque.
Step 109

Attach the engine wiring harness.

Step 110

Connect the ground wire.
Step 111

Screw on the ground wire fastener. Use a combination spanner #13.
Step 112

Treat the engine wiring harness connectors. Use dielectric grease.
Step 113

Connect the engine wiring harness connector.
Step 114

Attach the clutch cable.
Step 115

Install the battery tray.
Step 116

Screw in the battery tray fasteners. Use a drive socket #10. Use a ratchet wrench.
Step 117

Install the battery.
Step 118

Screw in the battery fastener. Use a drive socket #13. Use a ratchet wrench.
Step 119

Attach the terminals to the battery.

Replacement: clutch kit – VW POLO (86C, 80). Tip from AUTODOC:
Be careful! Do not mix up the positive and the negative terminals of the car battery.
Step 120

Screw in the fasteners of the battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 121

Treat the battery terminals. Use dielectric grease.
Step 122

Run the engine for a few minutes. This is necessary in order to make sure that the component operates properly.

Step 123

Shut off the engine.

Step 124

Remove the fender protection cover.

Step 125

Close the hood.

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