Removing and installing clutch housing/differential — VW

Note:

Before starting work mount gearbox in repair stand => fig.
1
and drain oil

Important:
Before removing and installing clutch housing, protect seal from damage by shaft spline.
To do this fit a piece of sleeving over the shaft.
Oil filter plug 20 Nm
Adjusting ring, right
Mark before removing => fig.
4
Removing => fig.
5
Installing => fig.
7
Coat thread with MoS2 grease, dismantling and assembling =>page
39-4

Locking plate

Drive flange
Pulling off => fig.
3
Installing => fig.
8

Cap
Renew

Circlip
Renewing, installing => fig.
9

Washer
Input shaft, rear
Removing: remove circlip, push reverse gear back and screw shaft out
Installing: screw front rear shafts together then release one spline; push reverse gear on and fit new circlip
Wath different lengths => fig.
10

Hexagon head bolt M 8X46
With washer (6) 20 Nm

Drain plug 20 Nm
Hexagon head bolt M 8X28
With washer (4) 20 Nm

Clutch housing
Before removing: loosen left final drive adjusting ring to relieve preload in gearbox housing
Mark position of adjusting ring beforehand => fig.
4
Repairing =>page
34-51

Circlip
Renew

Stud
Reverse gear
Differential
Removing => fig.
6
Before removing: remove adjusting rings and rear input shaft, dismantling and assembling =>page
39-4

Gasket
Renew

Adjusting ring, left
Mark before removing => fig.
4
Removing => fig.
5
Installing => fig.
7
Coat thread with MoS2 grease, dismantling and assembling =>page
39-4

Gearbox housing with gear train
Dismantling and assembling gear train =>page
34-26

Fig.1
Mounting gearbox in repair stand

Beforehand: Remove gearshift lever and switch for reversing lights

Fig.2
Convert gearbox holder VW 352 in accordance with diagram

Fig.3
Pull drive flange out

A = 2 Screw M 8 x 30 bolts through the slots into the flange

Fig.4
Determining and marking position of adjusting ring

Before starting repair work which does not require the differential to be adjusted again afterwards, mark the position (arrow) of the adjusting rings in the gearbox housing and measure the depth to which they are screwed in with VW 382/7 and record the readings

Make one mark on the left side (crown wheel side) and two marks on right side

Beforehand: Remove gearshift lever and switch for reversing lights

Fig.5
Removing adjusting rings

Fig.6
Lift differential out

Fig.7
Installing adjusting rings

Screw adjusting rings into gearbox housing as previously marked, and set them to the marks made when removing and to the depth measured

Important:
Do not tighten the left-hand ring until the clutch housing has been fitted and the nuts tightened.
Fig.8
Installing drive flange

Fig.9
Installing circlip

Install washer and circlip

Press circlip into groove and ensure that washer is central

Fig.10
Identification of rear input shaft

Dim. a · Dim. b · Total length
1.6 l diesel engine · 3 mm · 287 mm
1.9 l carburetor engine · 27 mm · 298 mm