Clutch Cover, Removing

WARNING: This page is about a different variant/trim than selected.

Short Description

The cover seals the transmission from the outside. It is held in place by a lock ring. Remove the lock ring and pry out the cover. Always replace the cover and the lock ring. Never use a hammer to install the cover and never lubricate the center seal or touch it. If this should occur, the cover will certainly leak.

Fig 1: Attention: Never Oil Center Seal Or Touch With Hand

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The transmission must be removed in order to work on the cover.

-- Drain the oil.

Fig 2: Identifying Oil Drain And Inspection Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Up to transmission production date "September 20, 2004", transmissions with two plugs were installed.

Then, the second plug was deleted so that only the one plug -A- can be used to drain the oil or to adjust the oil level.

A plastic overflow tube is located in this hole (with a 8 mm hex socket head, tightening specification: 3 Nm). Its length determines the oil level in the transmission.

-- Remove the overflow tube -arrow- and let the oil drain.

Fig 3: Identifying Overflow Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

About 5 liters of oil will drain.

-- Reinstall the overflow tube and tighten it to 3 Nm.

-- Insert the oil drain plug and the new seal -arrow- and tighten it by hand.

Fig 4: Identifying ATF Inspection Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the transmission. Refer to one of the following:

GTI (2006-2009) with a 2.0L TFSI engine, refer to TRANSMISSION, REMOVING .

R32 (2008), refer to TRANSMISSION, REMOVING .

-- Secure the transmission to the assembly stand. Refer to TRANSMISSION, TRANSPORTING AND SECURING TO THE ASSEMBLY STAND .

-- If it is necessary, remove the filter.

Fig 5: Identifying Transmission Filter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

There are often uncertainties as to whether the filter must be replaced or not.

For the information on changing the oil filter, refer to WHEN TO CHANGE THE OIL FILTER . This can help when making this decision.

-- Insert the new filter with the seat facing downward and tighten the housing to 20 Nm.

Fig 6: Identifying Oil Filter O-Ring In Suction Collar

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- After repairing, you do not have to change the filter again when filling the oil.

Remove the clutch cover.

-- Pry out and remove the lock ring -2- for the clutch cover with a screwdriver -1- -arrow-.

Fig 7: Identifying Circlip And Clutch End Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Lift the clutch cover -2- through the opening in the starter with a screwdriver -1- or a pry bar -arrow- and then remove it.

Fig 8: Identifying Clutch End Cover, Starter Opening And Screwdriver

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install a >>new<< cover only. Refer to CLUTCH END COVER, INSTALLING .