Clutch Housing, Servicing

Clutch housing, servicing, 02M, 5 and 6 Spd. M/T

Special tools and equipment:

- VW 407 Press tool
- 30-21 Sleeve
- 3176 Centering mandrel
- T40008 Press piece
1 - Kukko 21/2 Internal puller
1 - Kukko 21/4 Internal puller
4 - Kukko 22/1 Counter support
4 - Kukko 22/2 Counter support





1. Bushing
^ For selector rods
^ Replace each time after removing
^ Pulling out go to Fig. 1
^ Driving in go to Fig. 2

2. Reverse gear selector fork axle
^ Axle cannot be removed with workshop tools
^ Pressing axle into clutch housing go to Fig. 7

3. Needle bearing
^ Replace each time after removing
^ Pulling out go to Fig. 3
^ Pressing in go to Fig. 4

4. Dowel sleeve
^ Qty. 2

5. Clutch housing
^ If replaced: go to Adjustment overview

6. Input shaft oil seal
^ Removing go to Fig. 5
^ Installing go to Fig. 6

7. Oil seal
^ Replacing

8. Shim
^ For differential
^ Always 0.65 mm thick

9. Outer race/tapered roller bearing
^ If replaced: adjust differential

10. Oil deflector ring
^ Installed position: shoulder on drilling faces output shaft

11. Outer race/tapered roller bearing
^ If replaced: adjust 1st-4th gear output shaft

12. Outer race/tapered roller bearing
^ If replaced: adjust 5th, 6th and reverse gear output shaft

13. Shim
^ Always 0.65 mm thick

14. Outer race/tapered roller bearing
^ If replaced: adjust input shaft
^ Transmissions from build date 06 04 0 secured with locking plate and bolt
^ Bolt, 12 Nm; always replace

15. Magnet
^ Held in place by housing joint surface

16. Protective cap
^ Installed only in clutch housing of 4-Cyl. engine





Fig. 1 Pulling out selector rod bushing
A - Counter support, e.g. Kukko 22/1
B - Internal extractor 14.5 to 18.5 mm, e.g. Kukko 21/2





Fig. 2 Driving selector rod mounting bushing in flush





Fig. 3 Pulling needle bearing out of clutch housing
A - Counter support, e.g. Kukko 22/2
B - Internal extractor 23.5 to 30 mm, e.g. Kukko 21/4

Note: The needle bearing is destroyed during removal and must be replaced.





Fig. 4 Pressing needle bearing -A- into clutch housing
- Before pressing in, lay reverse shaft thrust washer -B- on needle bearing.





Fig. 5 Removing output shaft oil seal
- Pry oil seal out carefully with a screwdriver.
- When transmission is disassembled, oil seal can be removed with sleeve 30-21.





Fig. 6 Driving in input shaft oil seal flush





Fig. 7 Pressing reverse gear selector fork shaft into clutch housing