Gearbox must be inclined slightly to the rear so that gear oil does not escape after flange shaft (left-side) is removed.
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Unscrew bolts -arrows- on mounting bracket for flange shaft (left-side).
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Remove flange shaft from gearbox in direction of -arrow A-. Keep shaft end -2- centered in opening on front final drive -arrow 3-.
Caution
Risk of damage to oil seal.
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If you do not keep the shaft centered when pulling it out further, the splines of the shaft -2- will fall against the inner oil seal -arrow 3- between the differential and the gearbox housing.
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If oil seal is damaged, it must be renewed → Chapter.
Note
If the flange shaft (left-side) cannot be removed by hand, pull it out carefully using multi-purpose tool -VW 771-.
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To do this, secure plate of puller -T10037- to flange shaft -arrows- and attach plate to spindle of multi-purpose tool -VW 771- (nuts -A-).
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Attach extractor -T40176- to clutch module -A- using nut -B--arrow-.
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Turn extractor -T40176- upwards.
Caution
Risk of damage to oil seals and needle bearing in dual-mass flywheel.
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The clutch module weighs approx. 20 kg.
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Keep firm hold of the bottom of the clutch module, as shown in the illustration, to prevent the clutch module from tilting over.
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When removing and installing the clutch module, take care not to damage the oil seals and needle bearing in the dual-mass flywheel -arrow-.
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Renew oil seals or needle bearing if damaged → Chapter.
Take care not to damage flange for drive plate on dual-mass flywheel.
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Do not put down clutch module with flange -arrow- for drive plate facing downwards.
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This could bend the flange -arrow- for the drive plate, which would cause problems with clutch operation.
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Put clutch module down carefully, e.g. on work bench, with pressure plate facing downwards.
Installing clutch module
Installation is carried out in reverse sequence; note the following:
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Grease clutch release bearing according to specifications → Fig..
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Thoroughly clean flange shaft (left-side), area of gearbox housing leading to differential -arrow A- and oil seal -arrow B-.
Note
If oil seal between differential and gearbox housing -arrow B- is damaged, it must be renewed → Chapter.
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Pack space between sealing lip and dust lip -arrow B- half full with sealing grease -G 052 128 A1-.
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Clean input shaft -arrow-.
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Apply a thin coat of grease for clutch plate splines -G 000 100- to the splines of the input shaft.
Caution
Before installing clutch module, remove grease from input shaft bearing journal -arrow- as far as splines.
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Carefully slide clutch module onto input shaft taking care to keep clutch module straight.
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Detach extractor -T40176- from clutch module.
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Turn clutch module -1- so that you can see opening to differential -arrow 3-.
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Slide flange shaft (left-side) into gearbox in direction of -arrow B- (keep end of shaft -2- centered while guiding it into oil seal on final drive -arrow 3-).
Caution
Risk of damage to oil seal.
t
If you do not keep the shaft centered, the splines of the shaft -2- will damage the oil seal -arrow 3- between the differential and the gearbox housing.
t
If oil seal is damaged, it must be renewed → Chapter.