Golf Mk4
| Repairing clutch housing |
| Special tools and workshop equipment required |
| t | Drift -VW 295- |
| t | Puller -VW 228 B- |
| t | Drift -VW 222 A- |
| t | Puller hooks -T20143/1- |
| t | or |
| t | Oil seal extractor lever -VW 681- |
| t | Sleeve -30 - 21- |
| t | Thrust pad -VW 510- |
| 1 - | Oil drain plug, 25 Nm |
| q | Without magnet. |
| 2 - | Dowel sleeve |
| q | (Qty. 2) |
| 3 - | Shim S2 |
| q | Always 1 mm thick |
| 4 - | Tapered roller bearing outer race |
| q | For differential |
| q | Driving in and out → Chapter. |
| q | If renewed, adjust differential → Chapter |
| 5 - | Magnet |
| q | Held in place by housing joint surface |
| q | Insert with sealant -AMV 188 200 03-. |
| 6 - | Shim |
| q | For output shaft |
| q | Adjustment overview → Chapter |
| 7 - | Tapered roller bearing outer race |
| q | For output shaft |
| q | Driving in and out → Chapter. |
| q | If replaced: Adjust output shaft → Chapter. |
| 8 - | Needle bearing |
| q | For input shaft |
| q | Pulling out → Fig. |
| q | Driving in → Fig. |
| 9 - | Hexagon bolt, 25 Nm |
| q | With locking teeth below bolt head. |
| 10 - | Reverse lever |
| 11 - | Compression spring |
| 12 - | Reverse lever support |
| 13 - | Sliding piece |
| 14 - | Starter bush |
| q | Not fitted in all gearboxes. |
| q | Allocate according to → Electronic parts catalogue “ETKA”. |
| q | Pulling out → Fig. |
| q | Driving in → Fig. |
| q | Can be renewed with gearbox installed. |
| 15 - | Plug |
| q | Green - Clutch diameter 210 mm. |
| q | White - Clutch diameter 190 and 200 mm. |
Note| It is important to allocate parts correctly e.g. when exchanging gearbox or transferring clutch. |
| Consequences if incorrect sealing plug is installed: |
| 1. White sealing plug - 210 mm Ø clutch |
| – | The TDC sensor will be destroyed and the markings on the flywheel damaged. Parts of TDC sensor will be lying in clutch chamber. |
| 2. Green sealing plug - 190 and 200 mm Ø clutch |
| – | Tester does not display a readout or readout is inaccurate or fluctuates. |
| 16 - | Cap |
| 17 - | Clutch housing |
| q | Insert oil strainer → Fig.. |
| q | When replacing: → Chapter, Adjustment overview |
| q | Differing assignment of bolt holes depending on engine → Chapter, Torque specifications. |
| 18 - | Input shaft seal |
| q | Pulling out → Fig. |
| q | Driving in → Fig. |
| 19 - | Sleeve |
| q | For seal → Item. |
| q | Removing → Fig.. |
| q | Driving in → Fig. |
| 20 - | Drive flange oil seal |
| q | Renewing → Chapter |
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