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.
• Always replace if removed.
• Removing, refer to => [ Removing the selector shaft bushing ].
• Installing, refer to => [ Installing the selector shaft bushing all the way to the tool stop ].
2 Selector Shaft, for the Reverse Gear Selector Fork
• The shaft cannot be removed with shop tools.
• A new shaft must be installed when using a new clutch housing. Refer to => [ Installing the selector shaft for the reverse gear selector fork into the clutch housing ].
• Mount the reverse gear shift 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 Plastic Cover.
• Bearing on the selector shaft for the 5th and 6th gear selector 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 Plastic Cover.
• Refer to the Parts Catalog.
3 Needle Sleeve
• For the reverse gear shaft.
• Always replace if removed.
• 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 shafts and differential. Refer to => [ Adjustment Overview ] Adjustment Overview.
6 Input Shaft Seal
• Removing, refer to => [ Removing the input shaft seal ].
• Installing, refer to => [ Install the input shaft seal until 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 circumference faces the seal - item 7 -.
9 Outer Race/Tapered Roller Bearing
• For the differential.
• Removing and installing, refer to => [ Differential ] Service and Repair.
• When replacing: adjusting the differential. Refer to => [ Differential, Adjusting ] Differential, Adjusting.
10 Oil Deflector Washer
• Installed position: The shoulder on the hole faces the output shaft.
11 Outer Race/Tapered Roller Bearing
• For the 1st to 4th gear output shaft.
• Removing and installing, refer to => [ Output Shaft, 1st to 4th Gears ] Output Shaft, 1st to 4th Gears.
• When replacing: adjust the output shaft for 1st to 4th gear. Refer to => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting.
12 Outer Race/Tapered Roller Bearing
• For the 5th, 6th and reverse gear output shaft.
• Removing and installing, refer to => [ 5th, 6th and Reverse Gears Output Shaft Overview ] 5th, 6th and Reverse Gears Output Shaft Overview.
• When replacing: adjust the output shaft for 5th/6th and reverse gear. Refer to => [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.
13 Adjusting Washer
• For the 5th, 6th and reverse gear output shaft.
• Always 0.65 mm thick.
14 Cylindrical Roller Bearing
• For the input shaft
• Removing and installing, refer to => [ Input Shaft Overview ] Input Shaft Overview.
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 all the way to the tool stop
Removing the needle sleeve from the clutch housing
A Counter support, for example, Kukko support (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 until flush
Installing the selector shaft for the reverse gear selector fork into the clutch housing
