Clutch Housing, Servicing

Clutch housing (transmission as of approx. 04.2003), servicing, 02M/02Y, 5 & 6 Speed M/T, AWD





Special tools, testers and auxiliary items required
^ Punch VW 407
^ Sleeve 30-21
^ Mandrel T10169
^ Thrust piece T40008
^ - 1 - Internal extractor Kukko 21/2 and Kukko 21/4
^ - 4 - Support Kukko 22/2

Clutch housing, assembly overview





1 - Bearing bushing
^ For shift rods
^ Pulling out
^ Driving in

2 - Shaft for reverse gear shift fork
^ Shaft cannot be removed with workshop equipment
^ When using a new clutch housing, a new axle must be pressed in

3 - Needle sleeve
^ For reverse shaft
^ Always replace after removal
^ Pulling out
^ Pressing in

4 - Alignment bushing
^ Qty. 2

5 - Clutch housing

6 - Seal for input shaft
^ Removing
^ Installing

7 - Oil guide piece
^ Pry out using screwdriver
^ Fits only in one position

8 - Washer
^ For differential

9 - Tapered roller bearing outer race
^ For differential

10 - Oil deflector ring
^ Installed position: Shoulder at hole points toward output shaft

11 - Tapered roller bearing outer race
^ For output shaft for 1st to 4th gear

12 - Tapered roller bearing outer race
^ For output shaft for 5th/6th and reverse gear

13 - Washer
^ For output shaft for 5th/6th and reverse gear
^ 0.65 mm thick

14 - Cylindrical roller bearing
^ For input shaft
^ Removing and installing

15 - Magnet
^ Held by housing joint surfaces

16 - Plug
^ Only installed on clutch housing for 4-cylinder engine





Pulling out shift rod bearing bushing
A - Support Kukko 22/1
B - Internal puller 14.5 to 18.5 mm Kukko 21/2





Driving in shift rod bearing bushing
- Drive in bearing bushing for shift rod up to tool stop.





Pulling needle sleeve off clutch housing
A - Support Kukko 22/2
B - Internal puller 23.5 to 30 mm Kukko 21/4

Note: Needle sleeve is destroyed when removed and must be replaced.





Pressing in needle sleeve into clutch housing
- During pressing sequence, place thrust washer - B - for reverse shaft on needle sleeve - A -.





Removing input shaft seal
- Carefully pry out seal using a screwdriver.

Note: Seal can only be removed using sleeve 30-21 when transmission is disassembled.





Drive in input shaft seal
- Drive in sealing ring flush for input shaft.





Press shaft for reverse gear shift fork into clutch housing





Pulling cylindrical roller bearing off clutch housing
- When pulling off, press together seal - arrow - of cylindrical roller bearing using pliers - C -.
A - Support Kukko 22/2
B - Internal puller 30 to 37 mm Kukko 21/5





Pressing cylindrical roller bearing into clutch housing
- When pressing in circlip - arrow - of cylindrical roller bearing, compress using pliers - A -.
- Remove pliers before cylindrical roller bearing is in installation position. Circlip must engage into groove of clutch housing.