Servicing clutch housing for vehicles with engines of 111 kW and above — VW

Special tools and workshop equipment required

VW 244 B Fitting sleeve
VW 455 Fitting sleeve
VW 519 Tube
VW 548 Clamping piece
3301 Assembly tool
3350 Assembly tool

Special tools and workshop equipment required

3176 Centring mandrel
3346 Assembly tool
3349 Puller
V.A.G 1331 Torque wrench
1 - Kukko 21/2 Internal puller
4 - Kukko 22/2 Counter support

Hexagon bolt, 25 Nm
Oil pan
Installing => Fig.
1

Selector rod guide
Installing => Fig.
1

Outer race/taper roller bearing
For output shaft
Removing and installing
=> Page
35-36
If renewed: Adjust output shaft
=> Page
35-52

Shim S1
For output shaft
Adjustment overview
=> Page
39-49

Outer race/taper roller bearing
For input shaft
Removing and installing
=> Page
35-8
If replaced: Adjust input shaft
=> Page
35-16

Magnet
Held in place by housing joint surface

Dowel sleeve
Qty. 2

Input shaft oil seal
Removing => Fig.
2
Installing => Fig.
3

Bonded rubber mounting
Pulling out => Fig.
4
Pulling in => Fig.
5

Oil seal
Renewing => Page
39-1

O-ring
Renew

Speedometer sender
Hexagon bolt

Clutch housing
If replaced: =>Adjustment overview, Page
39-49

Oil seal
Always renew

Oil drain plug, 25 Nm
Bush
For selector rods
Pulling out => Fig.
6
Driving in => Fig. 7

Oil deflector ring
Installation position: Step on internal diameter points to seal

Outer race/taper roller bearing
For differential
Removing and installing
=> from Page
39-29
If renewed: Adjust differential
=> Page
39-55

Fig.1
Installing oil collector and selector rod guide

Insert selector rod guide -A- with centralizing shoulder into hole in clutch housing.
Insert oil pan -B- into housing cut-out next to differential taper roller bearing outer race.
Secure oil pan and selector rod guide with a hexagon head bolt -C-.

Fig.2
Removing input shaft oil seal.

Lever oil seal out carefully with a screwdriver.

Fig.3
Driving in input shaft oil seal.

Fig.4
Pulling out bonded rubber mounting

Note:

It is important to grease spindle with Molybdenum grease before using.

Fig.5
Pulling in bonded rubber mounting

A -
Bonded rubber mounting

Fig.6
Pulling out mounting bush for selector rod

A - Counter support, e.g. Kukko 22/1

B - Internal extractor 14.5 ... 18.5 mm, e.g. Kukko 21/2

Fig.7
Driving selector rod mounting bush in flush