Clutch Housing, Repairing

Clutch housing, repairing





Special tools and equipment
^ VW 407 punch
^ 30 21 sleeve
^ 3176 centering mandrel
^ T40008 pressure piece
^ 1 - Kukko 21/2 extractor
^ 1 - Kukko 21/4 extractor
^ 4 - Kukko 22/1 support
^ 4 - Kukko 22/2 support





1. Bushing
^ For shift rods
^ Replace after removal
^ Pulling out - Fig 1
^ Driving in - Fig. Fig. 2
2. Shaft for shift fork reverse gear
^ Shaft cannot be removed using shop equipment
^ Pressing shaft into clutch housing
3. Needle sleeve
^ Replace after removal
^ Pulling out - Fig 3
^ Pressing in - Fig 4
4. Alignment bushing
^ 2 pieces
5. Clutch housing
6. Oil seal for input shaft
^ Removing Fig. 5
^ Installing - Fig. 6
7. Oil guide piece
^ Pry out using screwdriver
^ Only fits in one position
8. Shim
^ For differential
^ Always 0.65 mm thickness
9. Tapered roller bearing outer race
^ For differential
^ Removing and installing, Refer to Differential, Assembly, Service and Repair
^ In case of replacement: adjusting differential, Refer to Differential, Assembly, adjustments
10. Oil deflection plate
^ Installation position: shoulder at hole points in direction of pinion shaft
11. Tapered roller bearing outer race
^ For pinion shaft 1st to 4th gear
^ Removing and installing, Refer to Overhaul Subassemblies, Pinion Shaft 1ST to 4TH Gear, Disassembling and Assembling
^ In case of replacement: adjust pinion shaft 1st to 4th gear , Refer to Overhaul Subassemblies, Pinion Shaft 1ST to 4TH Gear, Adjusting
12. Tapered roller bearing outer race
^ For pinion shaft 5th/6th and reverse gear
^ Removing and installing, Refer to Overhaul Subassemblies,5TH/6TH and Reverse Gear Pinion Shaft, Disassembling and Assembling
^ In case of replacement: adjust pinion shaft 5th/6th and reverse gear5TH/6TH and Reverse Gear Pinion Shaft, Adjusting
13. Shim
^ For pinion shaft
^ Always 0.65 mm thickness
14. Tapered roller bearing outer race
^ For input shaft
^ Removing and installing , Refer to Overhaul Subassemblies, Input Shaft, Disassembling and Assembling
^ In case of replacement: adjust input shaft, Refer to Overhaul Subassemblies, Input Shaft Adjusting
15. Magnet
^ Is held in place via housing separating surface
16. Plug
^ Only installed on clutch housing for 4 cylinder engines





Fig. 1 Pulling out shift rod bushing
A- support, z. B. Kukko 22/1
B - extractor 14.5 ... 18.5 mm, z. B. Kukko 21/2





Fig. 2 Drive in shift rod bushing flush





Fig. 3 Pulling out needle sleeve from clutch housing
A- support, i.e. Kukko 22/2
B - extractor 23.5-30 mm, z. B. Kukko 21/4

Notes: Needle sleeve is destroyed during removal and must be replaced.





Fig. 4 Pressing needle sleeve - A - into clutch housing
- Place thrust washer - B - from reverse shaft onto needle sleeve during installation process.





Fig. 5 Removing O-ring for input shaft
- Carefully pry out O-ring using screwdriver.
- On a disassembled transmission O-ring can be removed using 30-21 sleeve.





Fig. 6 Drive in ring input shaft flush
- Fill gap between seal in lip and dust lip with sealant G 052 128 A1.





Fig. 7 Press in shaft for shift fork reverse gear into clutch housing