Clutch housing, servicing as of transmission manufacture date 190503: Notes

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools - Clutch Housing, Servicing As Of Transmission Manufacture Date 190503

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Punch VW 407
Sleeve 30-21
Drift T10169
Thrust piece T40008

Internal puller 1 - Kukko 21/2
Internal puller 1 - Kukko 21/4
Support 4 - Kukko 22/2

Fig 2: Exploded View Of Clutch Housing Components As Of Transmission Manufacture Date 190503

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Bushing

For selector rods
Pulling out: Pulling out 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 workshop 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 sleeve

For reverse shaft
Always replace after removal
Pulling out: Pulling needle sleeve off clutch housing
Pressing in: Pressing needle sleeve - A - into clutch housing

4 - Alignment bushing

Qty. 2

5 - Clutch housing

When replacing: Adjust output shafts and differential → Adjustment overview for manual transmission

6 - Seal for input shaft

Removing: Removing seal for input shaft
Installing: Driving in seal for input shaft flush

7 - Oil guide piece

Remove using screwdriver
Fits only in one position

8 - Washer

For differential

9 - Tapered roller bearing outer race

For differential
Removing and installing: Pulling outer race/tapered roller bearing off clutch housing
When replacing: Adjust differential → Differential, adjusting

10 - Oil deflector ring

Installed 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 for 1st to 4th gear, disassembling and assembling
When replacing: Adjust output shaft for 1st to 4th gear → Output shaft for 1st to 4th gear, adjusting

12 - Tapered roller bearing outer race

For output shaft for 5th/6th and reverse gear
Removing and installing: Pulling outer race/tapered roller bearing off clutch housing
When replacing: Adjust output shaft for 5th/6th and reverse gear → Output shaft for 5th/6th and reverse gears, adjusting

13 - Washer

For output shaft for 5th/6th and reverse gear
Always 0.65 mm thick

14 - Cylindrical roller bearing

For input shaft
Removing and installing: Pulling cylindrical roller bearing off clutch housing

15 - Magnet

Held by housing joint surfaces.

16 - Concealment cap

Installed only on clutch housing for 4-cylinder engine