Volkswagen Workshop Service and Repair Manuals

Removing clutch end cover Brief description

The cover seals the gearbox. It is held in place by a retaining ring. After the retaining ring has been removed, the cover can be levered out of its seat. Cover and retaining ring must always be renewed. Never install a new cover with a hammer and never oil the centre seal or touch it with a hand! However, if this should happen, the cover is certain to leak! The gearbox must be removed for work on cover.

–  Drain oil. To gearbox manufacture date „20 September 2004“, gearboxes were constructed with 2 plugs. The second plug was then discontinued, and oil can only be drained and the level checked with plug -A-. A plastic overflow tube (with 8 mm hexagon socket head bolt, torque setting 3 Nm) is located in this hole. Its length determines the oil level in the gearbox.

–  Remove oil level pipe -arrow- and allow oil to run out. Approximately 5 litres of oil will run out. –  Screw oil level pipe back in to stop and tighten to 3 Nm.

–  Locate oil drain plug with new seal -arrow- and hand-tighten . –  Remove gearbox → Chapter. –  Secure gearbox to assembly stand → Chapter.

–  Remove the filter if necessary. Often, doubts arise as to whether the filter must be renewed or not. The notes on the oil filter change → Chapter can help you in reaching this decision.

–  Insert new filter with shoulder downwards and tighten cover to 20 Nm.

–  Following repair work, it is not necessary to change the filter again when filling oil. Remove clutch end cover.

–  Lever out retaining ring -2- of clutch end cover using screwdriver -1--arrow- and remove.

–  Lever clutch end cover -2- out through opening for starter motor using screwdriver -1- or tyre lever -arrow- and remove clutch end cover. Install only a »new« cover → Chapter.