All-wheel drive - repairing clutch housing — VW

VW
CC
2010
Eos
2006
Golf
2004
Golf
2009
Golf Plus
2005
Golf Plus
2009
Passat
2006
Passat CC
2009
Touran
2003
Power transmission
6-speed manual gearbox 02Q
Edition
04.2013
All-wheel drive - repairing clutch housing
Special tools and workshop equipment required
Press tool
VW 407
Sleeve
30-21
Drift
T10168
Thrust piece
T40008
Internal puller
1 - Kukko 21/2
Internal puller
1 - Kukko 21/4
Counter support
4 - Kukko 22/2
Bearing bush
For selector rods
Renew each time after removing
Pulling out
Fig.
Driving in
Fig.
Reverse gear selector fork axle
Place reverse gear selector fork onto shaft
Fig.
Axle cannot be removed with workshop tools
If a new clutch housing is used, a new axle must be pressed in
Fig.
If shaft is not present, mounting on selector rod for selector fork for 5th and 6th gear
Fig.
Allocation of components via
Electronic parts catalogue
Needle bearing
For reverse shaft
Renew each time after removing
Pulling out
Fig.
Pressing in
Fig.
Dowel sleeve
Qty. 2
Clutch housing
If renewed: adjust output shafts and differential
Chapter
Input shaft seal
Renewing
Chapter
When gearbox is dismantled, oil seal can be removed with
sleeve
30-21
Seal
Between gearbox and bevel box.
Renewing with manual gearbox installed
Chapter
.
Pull out with
oil seal extractor lever
VW 681
or
extractor tool
T20143/2
.
With gearbox dismantled, can be driven in to stop with
thrust piece
T40007
.
Washer
For differential
Installation position: shoulder on inner circumference faces seal
Item
Tapered roller bearing outer race
For differential
Removing and installing
Chapter
If renewed, adjust differential
Chapter
Oil deflector ring
Installation position: shoulder on hole faces output shaft
Tapered roller bearing outer race
For output shaft for 1st through 4th gears
Removing and installing
Chapter
If renewed, adjust output shaft for 1st through 4th gears
Chapter
Tapered roller bearing outer race
For output shaft for 5th, 6th and reverse gears
Removing and installing
Chapter
If renewed, adjust output shaft for 5th, 6th and reverse gears
Chapter
Washer
For output shaft for 5th, 6th and reverse gears
Always 0.65 mm thick
Cylindrical roller bearing
For input shaft
Removing and installing
Chapter
Magnet
Held in place by housing joint surface.
Cap
Not fitted in all clutch housings
Pulling out selector rod bearing bush
A
Counter support
, e.g.
Kukko 22/1
B
Internal puller, 14.5 … 18.5 mm
, e.g.
Kukko 21/2
Driving in selector shaft bearing bush to stop of tool
Pulling needle bearing out of clutch housing
A
Counter support
, e.g.
Kukko 22/2
B
Internal puller, 23.5 … 30 mm
, e.g.
Kukko 21/4
Note
The needle bearing is destroyed during removal and must be renewed.
Pressing needle bearing
A
into clutch housing
Before pressing in, lay reverse shaft thrust washer
B
on needle bearing.
Pressing reverse gear selector fork shaft into clutch housing