Get OperationandHousing -> 13 Clutch Housing, Servicing Guide for Volkswagen Jetta 4 Door Fourth Generation (1999-2005)

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Clutch Housing, Servicing

Special tools and workshop equipment required

♦ Press Piece - Rod - VW407-

♦ Bushing Driver - Selector Shaft - T10168-

♦ Seal Installer - Driveshaft - T40008-

♦ Puller - Kukko Internal - 14-19mm - 21/2-

♦ Puller - Kukko Internal - 20-30mm - 21/4-

♦ Puller - Kukko Counterstay - 22/1-

♦ Puller - Kukko Counterstay - 22/2-

1 - Bearing Bushing

❑ For the selector rods

❑ Always replace if re‐

moved

❑ Removing. Refer to

⇒ Fig. ““Removing the

Shift Rod Bearing Bush‐

ing”“ , page 271 .

❑ Installing. Refer to

⇒ Fig. ““Installing the

Shift Rod Bearing Bush‐

ing All the Way onto the

Tool”“ , page 271 .

2 - Axle for the Reverse Gear

Shift Fork

❑ The axle cannot be re‐

moved with workshop

tools.

❑ A new axle must be in‐

stalled when using a

new clutch housing. Re‐

fer to

⇒ Fig. ““Installing the

Axle for the Reverse

Gear Shift Fork into the

Clutch Housing”“ ,

page 272

❑ Mount the reverse gear

shift fork on the axle.

Refer to

⇒ Fig. ““The Reverse

Gear Shift Fork -1- is

Mounted on the

Axle -2- behind the 5th

and 6th Gear Shift

Rod -3-.”“ , page 254

❑ Bearing on the shift rod

for the 5th and 6th gear shift fork. Refer to

⇒ Fig. ““The Reverse Gear Shift Fork -1- is Mounted on the Gearshift Rod with the 5th and 6th Gear Shift

Fork -2-.”“ , page 254

❑ Refer to the Parts Catalog.

3 - Needle Sleeve

❑ For the reverse shaft

❑ Always replace if removed

❑ Removing. Refer to ⇒ Fig. ““Removing the Needle Sleeve from the Clutch Housing”“ , page 271 .

13. Clutch Housing, Servicing

269

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

❑ Installing. Refer to ⇒ Fig. ““Installing the Needle Sleeve -A- into the Clutch Housing”“ , page 271 .

4 - Alignment Sleeve

❑ Quantity: 2

5 - Clutch Housing

❑ When replacing: adjust the output shafts and differential. Refer to

⇒ “4 Overview - Adjustment”, page 393

6 - Input Shaft Seal

❑ Removing. Refer to ⇒ Fig. ““Remove the Seal for the Input Shaft”“ , page 272 .

❑ Installing. Refer to ⇒ Fig. ““Installing the Seal for the Input Shaft”“ , page 272 .

7 - Seal

❑ FWD - for the right flange shaft

♦ Replace the right flange shaft for FWD. Refer to ⇒ “1.2 Right Flange Shaft Seal, Replacing”, page 370

❑ For the bevel box for AWD vehicles; between the manual transmission and the bevel box

♦ Replace if the manual transmission is installed and for AWD vehicles. Refer to

⇒ “2.3 Bevel Box Seal, Replacing, with Manual Transmission Installed”, page 375

♦ Remove using the Puller - Crankshaft/Power Steering Seal - 2 - T20143/2-

♦ Can be driven in to the stop with a Seal Installer - Crankshaft - T40007- in a disassembled transmission.

8 - Washer

❑ For the differential

❑ Installed position: shoulder on inner diameter faces toward seal -item 7- ⇒ Item 7 (page 270)

9 - Outer Race/Tapered Roller Bearing

❑ For the differential

❑ FWD, removing and installing. Refer to

⇒ “5.1 FWD Differential, Disassembling and Assembling”, page 394 .

❑ AWD, removing and installing. Refer to

⇒ “5.2 Differential, AWD, Disassembling and Assembling”, page 399 .

❑ When replacing: adjust the differential. Refer to ⇒ “5.3 Differential, Adjusting”, page 405

10 - Oil Deflector Ring

❑ Installed position: shoulder at hole points toward output shaft

11 - Outer Race/Tapered Roller Bearing

❑ Output shaft, 1st to 4th gears

❑ Removing and installing. Refer to

⇒ “2.2 Output Shaft, 1st to 4th Gears, Disassembling and Assembling”, page 321 .

❑ Adjust, if output shaft for 1st to 4th gear is replaced. Refer to

⇒ “2.3 Output Shaft 1st through 4th Gear, Adjusting”, page 340 .

12 - Outer Race/Tapered Roller Bearing

❑ Output shaft, 5th/6th and reverse gears

❑ Removing and installing. Refer to

⇒ “3.1 Overview - Input Shaft, 5th/6th and Reverse Gears”, page 344 .

❑ When replacing: adjust output shaft for 5th/6th and reverse gear. Refer to

⇒ “3.3 Output Shaft, 5th, 6th and Reverse Gears, Adjusting”, page 353 .

13 - Washer

❑ Output shaft, 5th/6th and reverse gears

❑ Always 0.65 mm thick

14 - Cylindrical Roller Bearing

❑ For the input shaft

❑ Removing and installing. Refer to ⇒ “1.1 Overview - Input Shaft”, page 310 .

15 - Magnet

❑ Held in place by housing joint surface

270

Rep. Gr.34 - Operation and Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

16 - Cap

❑ Not on all clutch housings

Removing the Shift Rod Bearing Bushing

A - Counter Support , for example Puller - Kukko Counterstay -

22/1-

B - 14.5 to 18.5 mm Internal Puller , for example Puller - Kukko

Internal - 14-19mm - 21/2-

Installing the Shift Rod Bearing Bushing All the Way onto the Tool

Removing the Needle Sleeve from the Clutch Housing

A - Counter Support , for example, Puller - Kukko Counterstay -

22/2-

B - Internal Puller - 23.5 - 30 mm , for example Puller - Kukko

Internal - 20-30mm - 21/4-

Note

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

be replaced.

Installing the Needle Sleeve -A- into the Clutch Housing

– While installing, place thrust washer -B- for the reverse shaft

onto the needle sleeve.

13. Clutch Housing, Servicing

271

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

6-Speed Manual Transmission 02Q - Edition 05.2013

Remove the Seal for the Input Shaft

Note

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

Installing the Seal for the Input Shaft

Installing the Axle for the Reverse Gear Shift Fork into the Clutch

Housing

272

Rep. Gr.34 - Operation and Housing

OperationandHousing -> 13 Clutch Housing, Servicing for Your Volkswagen Jetta 4 Door Fourth Generation (1999-2005)

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