Volkswagen Workshop Service and Repair Manuals

Repairing clutch housing, from gearbox date 19 05 3

Special tools and workshop equipment required

t	Press tool -VW 407-

t	Sleeve -30-21-

t	Drift -T10168-

t	Thrust piece -T40008-

t	Internal puller -1 - Kukko 21/2-

t	Internal puller -1 - Kukko 21/4-

t	Counter support -4 - Kukko 22/2-

1 -	Bearing bush

q	For selector rods

q	Pulling out → Fig.

q	Driving in → Fig.

2 -	Reverse gear selector fork axle

q	Axle cannot be removed with workshop tools

q	If a new clutch housing is used, a new axle must be pressed in → Fig.

3 -	Needle bearing

q	For reverse shaft

q	Renew each time after removing

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Dowel sleeve

q

Qty. 2

5 -	Clutch housing

q	If renewed: adjust output shafts and differential → Chapter

6 -	Input shaft seal

When gearbox is dismantled, oil seal can be removed with sleeve -30-21-.

q	Renewing → Item

7 -

Oil guide

q	Lever out with a screwdriver

q	Fits in one position only

8 -

Washer

q	For differential

q	Allocation → Electronic parts catalogue (ETKA)

q	Installation position: If there is a shoulder on inner circumference, it must face away from outer race of tapered roller bearing → Item

9 -	Tapered roller bearing outer race

q	For differential

q	Removing and installing → Fig.

q	If renewed, adjust differential → Chapter

10 -	Oil deflector ring

q	Installation position: shoulder on hole faces output shaft

11 -	Tapered roller bearing outer race

q	For output shaft for 1st through 4th gears

q	Removing and installing → Chapter

q	If renewed, adjust output shaft for 1st through 4th gears → Chapter

12 -	Tapered roller bearing outer race

q	For output shaft for 5th, 6th and reverse gears

q	Removing and installing → Fig.

q	If renewed, adjust output shaft for 5th, 6th and reverse gears → Chapter

13 -

Washer

q	For output shaft for 5th, 6th and reverse gears

q	Always 0.65 mm thick

14 -	Cylindrical roller bearing

q	For input shaft

q	Removing and installing → Fig.

15 -

Magnet

q	Held in place by housing joint surface

16 -

Cap

q	Not fitted in all clutch housings

Pulling out selector rod bearing bush A -  Counter support, e.g. -Kukko 22/1- B -  Internal puller, 14.5…18.5 mm, e.g. -Kukko 21/2-

Driving in selector shaft bearing bush to stop of tool

Pulling needle bearing out of clutch housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 23.5…30 mm, e.g. -Kukko 21/4-   Note The needle bearing is destroyed during removal and must be renewed.

Pressing needle bearing -A- into clutch housing –  Before pressing in, lay reverse shaft thrust washer -B- on needle bearing.

Pressing reverse gear selector fork shaft into clutch housing

Pulling cylinder roller bearing out of clutch housing –  When pulling out, squeeze together retaining ring -arrow- of cylindrical roller bearing, using pliers -C-. A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 30…37 mm, e.g. -Kukko 21/5-

Pressing cylindrical roller bearing into clutch housing –  When pressing in, squeeze together retaining ring -arrow- of cylinder roller bearing, using pliers -A-. –  Remove pliers before cylindrical roller bearing is in installation position. Retaining ring must engage in groove of clutch housing.