Clutch Housing
Clutch Housing
Special tools, testers and auxiliary items required
• Punch (VW 407)
• Drift (T10168)
• Thrust Piece (T40008)
• Kukko Extractor 14.5-18.5 mm (21/2)
• Kukko Extractor 23.5-30 mm (21/4)
• Kukko Support (22/1)
• Kukko Support (Kukko 22/2)
1 Bushing
• For the selector shafts.
• Replace after removing.
• Removing, refer to => [ Removing the Selector Shaft Bushing ].
• Installing, refer to => [ Installing the Selector shaft Bushing ].
2 Selector Shaft, for Reverse Gear Selector Fork
• The shaft cannot be removed with workshop tools.
• A new shaft must be installed when using a new clutch housing. Refer to => [ Installing the Shaft for the Reverse
Gear Selector Fork into the Clutch Housing ].
• Mount the reverse gear selector fork on the shaft. Refer to => [ The reverse gear selector fork is mounted on the axle behind the
5th and 6th gear selector shaft. ] Transmission, with a Sealing Cap Circlip or a Plastic Cover.
• Bearing on the selector shaft for the 5th and 6th gear shift fork. Refer to => [ The reverse gear selector fork is mounted on the selector shaft with the 5th and 6th
gear selector fork. ] Transmission, with a Sealing Cap Circlip or a Plastic Cover.
• Allocate the parts using the Parts Catalog.
3 Needle Sleeve
• For the reverse gear shaft.
• Replace after removing.
• Removing, refer to => [ Removing the Needle Sleeve from the
Clutch Housing ].
• Installing, refer to => [ Installing the Needle Sleeve into the
Clutch Housing ].
4 Alignment Sleeve
• Quantity: 2
5 Clutch Housing
• When replacing: adjust the output shaft and differential, refer to => [ Adjustment Overview ] 02Q Transmission.
6 Input Shaft Seal
• Removing, refer to => [ Removing the Input Shaft Seal ].
• Installing, refer to => [ Install the Input Shaft Seal Flush ].
7 Seal
• For the right flange shaft.
• Removing and installing, refer to => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
8 Washer
• For the differential.
• Installed position: the shoulder on the inner diameter faces the seal => [ (Item 7) Seal ].
9 Outer Race/Tapered Roller Bearing
• For the differential.
• Removing and installing, refer to => [ Differential ] Service and Repair.
• When replacing: adjust the differential, refer to => [ Differential, Adjusting ] Final Drive, Differential (02Q Transmission).
10 Oil Deflector Washer
• Installed position: shoulder at the hole points toward the output shaft.
11 Outer Race/Tapered Roller Bearing
• Output shaft, 1st to 4th gears.
• Removing and installing, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
• Adjust, if the output shaft for 1st to 4th gears is replaced. Refer to => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting.
12 Outer Race/Tapered Roller Bearing
• Output shaft, 5th, 6th and reverse gears.
• Removing and installing, refer to => [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.
• When replacing: adjust the output shaft for 5th/6th and reverse gears. Refer to => [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
13 Adjusting Washer
• Output shaft, 5th, 6th and reverse gears.
• Always 0.65 mm thick.
14 Sleeve
• For the input shaft.
• Removing and installing, refer to => [ Input Shaft ] Input Shaft.
15 Magnet
• Held in place by the housing joint surface.
16 Plug
• Not on all clutch housings.
Removing the Selector Shaft Bushing
A Counter support, for example, kukko support (22/1)
B Internal puller 14.5 to 18.5 mm, for example, kukko extractor 14.5-18.5 mm (21/2)
Installing the Selector shaft Bushing
Removing the Needle Sleeve from the Clutch Housing
A Counter-support, for example, kukko support (Kukko 22/2)
B Internal puller 23.5 to 30 mm, for example, kukko extractor 23.5-30 mm (21/4)
• The needle sleeve will get damaged when it is removed and must be replaced.
Installing the Needle Sleeve into the Clutch Housing
- While installing, place the thrust washer - B - for the reverse shaft onto the needle sleeve - A -.
Removing the Input Shaft Seal
• Use the drift to remove the seal with the clutch housing removed.
Install the Input Shaft Seal Flush
Installing the Shaft for the Reverse Gear Selector Fork into the Clutch Housing
