Transmission Housing and Clutch Housing
Transmission Housing and Clutch Housing
Special tools, testers and auxiliary items required
• Punch (VW 408 A)
• Sleeve (VW 472/2)
• Centering Mandrel (12 - 551)
• Thrust Pad (30 - 555)
• Threaded piece from the Seal Installer Set - Rear Diff (3066)
• Thrust Pad (3124)
• Centering Mandrel (12 - 551)
• Mandrel (2026)
• Thrust Piece (T40008)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Kukko Puller 65-160 mm (18/1)
• Kukko Separating Tool 12-75 mm (17/1)
1 Sleeve
• For the shift shaft.
• Removing.
• Installing.
2 Alignment Bushing
3 Magnet
• Held in place by the housing joint surface.
4 Cover
• Apply sealing paste (AMV 188 200 03) to the sealing surface before installing.
5 Lock Ring
• insert in roller bearing groove.
6 Lock Ring
• insert in roller bearing groove.
7 Roller Bearing
• For the input shaft.
• Removing and installing, see - item 21 -=> [ Cylindrical Roller Bearing ] Input Shaft.
8 Roller Bearing
• For the output shaft.
• Removing and installing, see - item 2 -=> [ Cylindrical Roller Bearing ] Output Shaft.
9 Clutch Housing
• When replacing: adjust the differential, refer to => [ Differential, Adjusting ] Adjustments.
10 Input Shaft Seal
• Pry out with a screwdriver.
• Installing.
11 Ball Stud
• 20 Nm
• Remove any grease already present.
• Grease with grease for clutch shaft splines (G 000 100).
12 Right Flange Shaft Seal
• Replace when the transmission is installed. Refer to => [ Right Flange Shaft and Seal ] Right Flange Shaft and Seal.
13 Sleeve
• For the seal.
• Removing.
• Installing.
14 Fill Plug
• Tightening specification, refer to => [ Different versions of
the Fill and Drain Plugs ] Service and Repair.
15 Adjusting Shim S2
• For the differential.
• Determining thickness, refer to => [ Differential, Adjusting ] Adjustments.
16 Outer Race/Tapered Roller Bearing
• For the differential.
• Removing and installing from/to the clutch housing. Refer to => [ Differential ] Service and Repair.
• When replacing: adjust the differential, refer to => [ Differential, Adjusting ] Adjustments.
17 Bolt
• 5 Nm + 90° (1/4) additional turn.
• Always replace.
18 Outer Race/Tapered Roller Bearing
• For the differential.
• Removing and installing from/to the transmission housing. Refer to => [ Differential ] Service and Repair.
• When replacing: adjust the differential, refer to => [ Differential, Adjusting ] Adjustments.
19 Adjusting Shim S1
• For the differential.
• Always 1 mm thick.
• Shim S1 is deleted as of production date 04 December 2006. Refer to => [ Shim S for
the Outer Race/Tapered Roller Bearing is Deleted as of Production
date 04 December 2006 ] Adjustments.
.
20 Alignment Bushing
21 Transmission Housing
• Shim S1 is deleted as of production date 04 December 2006. Refer to => [ Shim S for
the Outer Race/Tapered Roller Bearing is Deleted as of Production
date 04 December 2006 ] Adjustments.
• Outer race/tapered roller bearing seat adapted in transmission housing.
• When replacing: adjust the differential, refer to => [ Differential, Adjusting ] Adjustments.
22 Drain Plug
• Tightening specification, refer to => [ Different versions of
the Fill and Drain Plugs ] Service and Repair.
23 Seal
• For the left flange shaft.
• Replace when the transmission is installed. Refer to => [ Left Flange Shaft and Seal ] Left Flange Shaft and Seal.
Installing the Input Shaft Seal
Sleeve Seal, Removing
- Install the (VW 472/2) and the (30 - 555) on the differential.
- A - = puller, for example (18/1)
- B - = separating tool, for example, (17/1)
Sleeve Seal, Pulling In
A Threaded studs from (3066) installed in the differential threaded piece.
B M12 nut with washer
- Turn the nut - B - and pull the sleeve all the way over the (3124).
• If the transmission is disassembled, press the sleeve in, onto the stop using (3124).
Shift Shaft Sleeve - A -, Removing
Shift Shaft Sleeve - A -, Installing
