Servicing clutch housing — VW

Locking bolt, 40 Nm
For selector shaft

Dowel sleeve
Qty. 2

Outer race/taper roller bearing
For input shaft
Removing and installing
=> Page
35-4

Shim
For input shaft
Determining thickness => Page
35-13

Release shaft
Removing and installing
=> Page
30-28

Sealing bolt with plug

Breather pipe
Clutch housing
If replaced: =>Observe adjustment overview, Page
39-22
Modifications:
Gearboxes for vehicles with cable selector mechanism, additional threaded mounting point => Fig.
1
Different gearbox mounting flanges for petrol and Diesel engines => Parts catalogue

Input shaft oil seal
Removing => Fig.
3
Installing => Fig.
4

Guide sleeve
Bolt, 20 Nm
Release bearing
Removing and installing
=> Page
30-29

Mounting bush
Only in conjunction with petrol engine
Removing => Fig.
5
Installing => Fig.
6

Guide bush
Drive shaft with pinion
For speedometer

Flange shaft oil seal
Removing => Fig.
7
Installing => Fig.
8
Renewing with gearbox installed => page
39-5

Sleeve
For oil seal (Item
16
)
Removing => Fig.
9
Installing => Fig.
10

Oil seal
For selector shaft
Carefully lever out using screwdriver => fig.
11
Installing => fig.
12
Can be renewed with gearbox installed =>page
39-1

Front ball sleeve
For selector shaft
Removing and installing
=>Fig.
13

Selector shaft
Installation position: The countersunk (arrow) points towards selector sleeve (Item
21
)
Check seat of bearing and inner racer of roller bearing for burrs and damage
Grease sliding surfaces with
MoS2 grease
Adjusting => Page
34-114
Modification:
Gearboxes for vehicles with cable selector control, new selector finger mounting => Fig.
2

Selector sleeve
Adjusting => Page
34-114

Bolt, 25 Nm
Shim
For differential
Determining thickness => Page
39-23

Outer race/taper roller bearing
For differential
Removing and installing
=> Page
39-8
If replaced: Adjust differential
=> Page
39-23

Shim
For output shaft
Determining thickness => Page
35-36

Outer race/taper roller bearing
For output shaft
Removing and installing
=> Page
35-18

Rear ball sleeve
For selector shaft
Removing and installing
=>Fig.
14

Fig.1
Modified clutch housing for gearboxes used in conjunction with cable selector mechanism

The clutch housing is equipped with two threaded mounting points (arrows A and B) for mounting the relay lever/selector cable bracket.

Fig.2
Modified selector shaft for gearboxes used in conjunction with cable selector mechanism

The selector shaft has only one recess (arrow) to accept the selector finger securing bolt as opposed to previous selector shaft.

Note:

The selector shaft cannot be installed in previous gearboxes.

Fig.3
Pulling out output shaft oil seal.

Fig.4
Driving in output shaft oil seal.

Installation position:

2.5 mm below housing upper surface.

Fig.5
Pulling out starter bush.

Fig.6
Driving in starter bush.

Lubricate bush mounting before driving in.

Fig.7
Pulling in flange shaft oil seal.

Fig.8
Driving in flange shaft oil seal.

Use the relevant side of the tool for the seals.
Fill space between seal and dust lip with multi-purpose grease.

Fig.9
Lever out sleeve with screwdriver

Fig.10
Driving in sleeve

Fig.11
Levering out seal using screwdriver

Remove selector shaft.
To prevent damage to the selector shaft, wrap thin layer of insulation tape around it.
Push selector shaft in onto stop.
Carefully punch a hole in the middle of the seal (arrow) using a small screwdriver.
Then lever out the seal using a slightly larger screwdriver.

Remove insulation tape and check selector shaft for damage.

Fig.12
Press in seal onto stop

Lightly oil outer circumference of oil seal.
Fill space between sealing lip and dust lip with grease G 052 128 A1.
Carefully push seal over chamfer of selector shaft in a twisting motion.

Fig.13
Removing and installing front ball sleeve

Installation position:

10 mm below housing upper surface.

Fig.14 Removing and installing rear ball sleeve

Installation position:

The ball sleeve must be flush in the rear area with the mounting eye.