Volkswagen Workshop Service and Repair Manuals

Repairing gearbox housing cover

Special tools and workshop equipment required

t	Fitting tool -3128-

t	Press tool -VW 411-

t	Thrust plate -VW 402-

t	Centring mandrel -12-551-

t	Guide pin -10-15-

t	Tube -VW 418 A-

t  Drift sleeve -2009-

1 -	Sealing cover

q

Renew.

q	Removing: pierce and lever out.

q	Installing → Fig.

2 -	Release bearing

q	Can be renewed with gearbox installed.

3 -	Clutch lever

q	Fits in one position only

4 -	Small mounting bush

q	Pulling out → Fig.

q	Pressing in → Fig..

5 -	Securing clip

6 -	Needle bearing

7 -	Large mounting bush

q	Pressing out → Fig..

q	Pressing in → Fig..

8 -

Seal

q	Driving in → Fig.

q	Can be renewed with gearbox installed. To renew, remove release shaft → Item.

9 -	Release shaft

q	Removing: remove sealing cover → Item and securing clip → Item and pull out release shaft.

10 -	Gearbox housing cover

q	Only version with mounting bushes → Item and → Item is available as a replacement part.

11 -	Oil filler plug, 25 Nm

q	Without magnet.

Installing sealing cover   Note Sealing surface on gearbox housing cover must be free of grease.

Pressing out large mounting bush -A-

Pressing in large mounting bush

Pulling out small mounting bush A -  Internal puller, 10 … 14 mm, e.g. -Kukko 21/02- B -  Counter support, e.g. -Kukko 22/1-   Note Mounting bush will be damaged when pulled out. Therefore always renew.

Pressing in small mounting bush

Driving in release shaft seal –  Clamp gearbox housing cover in vice using protective vice clamps.