Clutch Housing, Servicing

Clutch Housing, Servicing

Special tools, testers and auxiliary items required

• Punch (VW 407)

• Drift (T10168)

• Thrust piece (T40008)

• Internal extractor (Kukko 21/2)

• Internal extractor (Kukko 21/4)

• Support (Kukko 22/1)

• Support (Kukko 22/2)





1 Bushing

• For selector rods

• Pulling out --> [ Pulling Out Bearing Bushing for Selector Rod ]

• Driving in --> [ Driving In Bushing for Selector Rod to Tool Stop ]

2 Axle for reverse gear shift fork

• Axle cannot be removed with shop equipment

• When using a new clutch housing, a new axle must be pressed in --> [ Press Axle for Reverse Gear Shift Fork Into Clutch Housing ]

3 Needle bearing

• For reverse shaft

• Always replace after removal

• Pulling out --> [ Pull Needle Sleeve Off Clutch Housing ]

• Pressing in --> [ Pressing Needle Sleeve Into Clutch Housing ]

4 Alignment bushing

• Quantity: 2

5 Clutch housing

• When replacing: Adjust output shafts and differential --> [ Adjustment Overview ] Adjustment Overview.

6 Input shaft seal

• Removing --> [ Removing Seal For Input Shaft ]

• Driving in --> [ Drive In Seal For Input Shaft Flush ]

7 Seal

• Replace --> [ Right Flange Shaft Seal ] Right Flange Shaft Seal.

8 Washer

• For differential

• Installation position: Shoulder on inner diameter faces toward seal --> [ 7 Seal ]

9 Tapered roller bearing outer race

• For differential

• Removing and installing --> [ Differential ] Service and Repair.

• When replacing: Adjusting differential --> [ Differential, Adjusting ] Differential, Adjusting.

10 Oil deflector ring

• Installation position: Shoulder at hole points toward output shaft

11 Tapered roller bearing outer race

• For output shaft for 1st to 4th gear

• Removing and installing --> [ Output Shaft, 1st through 4th Gears ] Output Shaft, 1st through 4th Gears.

• When replacing: Adjusting output shaft for 1st to 4th gear --> [ Output Shaft, 1st through 4th Gears, Adjusting ] Output Shaft, 1st through 4th Gears, Adjusting.

12 Tapered roller bearing outer race

• For output shaft for 5th/6th and reverse gear

• Removing and installing --> [ Output Shaft, 5th, 6th and Reverse Gears ] Output Shaft, 5th, 6th and Reverse Gears.

• When replacing: Adjusting output shaft for 5th/6th and reverse gear --> [ Output Shaft, 5th, 6th and Reverse Gears, Adjusting ] Output Shaft, 5th, 6th and Reverse Gears, Adjusting.

13 Washer

• For output shaft for 5th/6th and reverse gear

• Always 0.65 mm thick

14 Roller bearing

• For input shaft

15 Magnet

• Held in place by housing joint surface

16 Cap

• Installed only on clutch housing for 4-cylinder engine

Pulling Out Bearing Bushing for Selector Rod





A Support, e.g. (Kukko 22/1)
B Internal puller 14.5 to 18.5 mm, e.g. (Kukko 21/2)

Driving In Bushing for Selector Rod to Tool Stop





Pull Needle Sleeve Off Clutch Housing





A Support, e.g. (Kukko 22/2)
B Internal puller 23.5 to 30 mm, e.g. (Kukko 21/4)

• Needle sleeve is destroyed when it is removed and must be replaced.

Pressing Needle Sleeve - A - Into Clutch Housing





- During pressing sequence, place thrust washer - B - for reverse shaft on needle sleeve.

Removing Seal For Input Shaft





- Carefully pry out seal using screwdriver.

Sealing ring can also be removed using pulling hook (T20143).

Drive In Seal For Input Shaft Flush





Press Axle for Reverse Gear Shift Fork Into Clutch Housing