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
8 - Shim
^ For differential
^ Always 0.65 mm thick

9 - Outer race/tapered roller bearing
^ For differential
^ Removing and installing
^ If replaced: adjust differential

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





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

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

13 - Shim
^ For output shaft
^ Always 0.65 mm thick





14 - Outer race/tapered roller bearing
^ For input shaft
^ Removing and installing
^ 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