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Home >> Volkswagen >> 2005 >> Jetta TDI, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 24 (Controls, Housing - Manual Transmission 02Q (Sedan) (A5 Platform)) >> 34 Controls, Housing >> Disassembly And Assembly >> Clutch Housing

Clutch Housing

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Special tools and workshop equipment required 

Fig 1: Identifying Clutch Housing Remove/Install Components
GWWN34-10052Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Bushing 
    • For the selector shafts.
    • Replace after removing.
    • Removing, refer to Fig 2.
    • Installing, refer to Fig 3.
  2. Selector Shaft, for Reverse Gear Selector Fork 
    • The shaft cannot be removed with workshop tools.
    • A new shaft must be installed when using a new clutch housing. Refer to Fig 8.
    • Mount the reverse gear selector fork on the shaft. Refer to Figure.
    • Bearing on the selector shaft for the 5th and 6th gear shift fork. Refer to Figure.
  3. Needle Sleeve 
    • For the reverse gear shaft.
    • Replace after removing.
    • Removing, refer to Fig 4.
    • Installing, refer to Fig 5.
  4. Alignment Sleeve 
    • Quantity: 2
  5. Clutch Housing 
  6. Input Shaft Seal 
    • Removing, refer to Fig 6.
    • Installing, refer to Fig 7.
  7. Seal 
  8. Washer 
    • For the differential.
    • Installed position: the shoulder on the inner diameter faces the seal, see "Seal" in item:  7.
  9. Outer Race/Tapered Roller Bearing 
  10. Oil Deflector Washer 
    • Installed position: shoulder at the hole points toward the output shaft.
  11. Outer Race/Tapered Roller Bearing 
  12. Outer Race/Tapered Roller Bearing 
  13. Adjusting Washer 
    • Output shaft, 5th, 6th and reverse gears.
    • Always 0.65 mm thick.
  14. Sleeve 
    • For the input shaft.
    • Removing and installing, refer to INPUT SHAFT .
  15. Magnet 
    • Held in place by the housing joint surface.
  16. Plug 
    • Not on all clutch housings.
Fig 2: Identifying Kukko Tool Assembly To Pull Out Bearing Bushing For Selector Rod
GWWN34-1018Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter support, for example, kukko Support 22/1

B - Internal puller 14.5 to 18.5 mm, for example, kukko extractor 14.5-18.5 mm 21/2

Fig 3: Identifying Bushing For Selector Rod Driven In To Tool Stop
GWWN34-10307Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Fig 4: Identifying Kukko Support And Extractor To Pull Needle Bearing Off Clutch Housing
GWWN34-1020Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Counter-support, for example, kukko support 22/2

B - Internal puller 23.5 to 30 mm, for example, kukko extractor 23.5-30 mm 21/4

NOTE:

The needle sleeve will get damaged when it is removed and must be replaced.

Fig 5: Identifying Tool To Press-In Needle Bearing And Thrust Washer -B- To Needle Sleeve -A-
GWWN34-1021Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- While installing, place the thrust washer -B- for the reverse shaft onto the needle sleeve -A-.

Fig 6: Identifying Input Shaft Pried-Out Seal Using Extractor Lever T20143/1
GWWA34-0614Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

Use the drift to remove the seal with the clutch housing removed.

Fig 7: Identifying Tool To Drive-In Input Shaft Oil Seal Flush
GWWN34-1017Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Fig 8: Identifying Tool To Press-In Axle For Reverse Gear Shift Fork To Clutch Housing
GWWN34-1120Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
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