VW Touareg Front Rear-Differential

2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
REAR DIFFERENTIAL
Rear Final Drive
00 GENERAL, TECHNICAL DATA

DRIVETRAIN GUIDE
Fig. 1: Drivetrain Guide, Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Transfer case
 Transfer case, removing and installing --> Differential, removing and installing
2 - Drive shafts
Microsoft
Sunday, September 20, 2009 9:03:57
9:03:51 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
 Drive shafts, removing and installing --> Driveshafts, removing and installing
3 - Rear final drive
 Rear final drive, removing and installing --> Rear final drive, removing and installing
4 - Front final drive
 Front final drive, removing and installing --> Front final drive, removing and installing
TRANSFER CASE IDENTIFICATION
Transfer case identification
The transfer case 0AD is allocated to the automatic transmission 09D.
Off-road reduction gearing is integrated into the transfer case.
Switching between street gearing "HIGH" and off-road gearing "LOW" is accomplished with the transfer case
operating unit E473.
Code letters --> Code letters, transmission allocation, gear ratios, capacities.
Location on transfer case
Location on transfer case - arrow -
Fig. 2: Location On Transfer Case

Code letters - arrow 1 - and date of manufacture - arrow 2 - of transfer case
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fig. 3: Code Letters And Date Of Manufacture Of Transfer Case

Example GJJ 03 05 02
I I I I
I I I I
Code letters Day Month Year (2002) of
manufacture
Additional data depends on manufacture.
Code letters, transmission allocation, gear ratios, capacities
Transfer case 0AD

Code letters FKA FKB
Application Model Touareg 2003 --> Touareg 2003 -->
Engine 4.2 L - 228 kW 5.0 L - 3.2 L -162 kW
230 kW Turbo-Diesel
Transmission housing extension length 127.4 mm 139.9 mm
Capacities 0.85 liters
Transfer case 0AD

Code letters FKC GFG GFH
Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 -->
Engine 3.2 L -162 kW 4.2 L - 228 kW 4.9 3.2 L -162 kW
L - 230 kW Turbo-
Diesel
Transmission housing extension length 158.2 mm 127.4 mm 158.2 mm
Transfer case OAD

Code letters GJJ GJK
Microsoft

Engine 4.2 L - 228 kW 5.0 L - 3.2 L -162 kW
230 kW Turbo-Diesel
Transfer case 0AD

Code letters GJL GTM
Engine 3.2 L -162 kW 5.0 L - 230 kW Turbo-
Diesel
Transfer case 0AD

Code letters GTN GTP HCH
Engine 3.2 L -162 kW 3.2 L 3.2 L -162 kW 3.2 L 5.0 L - 230 kW
- 177 kW - 177 kW Turbo-Diesel
Transfer case OAD

Code letters HPW HPX
Engine 5.0 L - 230 kW Turbo- 5.0 L - 230 kW Turbo-
Diesel Diesel
Capacities
Transfer case OAD

Code letters HMX
Application Model Touareg 2003 -->
Engine 3.2 L -177 kW
Transmission housing extension length 158.2 mm
Transfer case 0AD

Code letters HXB HXE HXA
Engine 5.0 L - 230 kW 3.2 L -177 kW 4.2 L -228 kW 4.2 L
Microsoft
Turbo-Diesel -257 kW
Transfer case 0AD

Code letters HXC FKF
Engine 3.2 L -177 kW 3.2 L -177 kW
Transfer case 0AD

Code letters FKG FKF
Engine 3.2 L -177 kW 3.2 L -177 kW
FRONT FINAL DRIVE IDENTIFICATION
Front final drive identification
The front final drive 0AA is allocated to the automatic transmission 09D.
Front final drive identification, location
Location on front final drive - arrow -.
Fig. 4: Location On Front Final Drive

Microsoft
Code letters and date of manufacture of front final drive.
Fig. 5: Identifying Code Letters And Date Of Manufacture Of Front Final Drive
Example FKK 20 08 02
I I I I
I I I I
manufacture
Front final drive 0AA

Code letters FKK FKM FKN
Engine 4.2 L - 228 kW 3.2 L -162 kW 3.2 L 4.2 L -228 kW
-177 kW
Gear ratio: Z 1 : Z 2 Final drive 37 : 10 = 3.700 39 : 10 = 3.900 41 :10 = 4.100
Drive shaft flange dia. 114 mm 114 mm 114 mm
Electromechanical differential lock Without Without Without

Code letters FKQ FLH FLJ
Engine 3.2 L -162 kW 3.2 L 3.2 L -162 kW 3.2 L -162 kW 3.2 L
-177 kW -177 kW
Gear ratio: Z 1 : Z 2 Final drive 41 : 9 = 4.556 39 : 10 = 3.900 41 : 9 = 4.556
Microsoft

Electromechanical differential lock Without With With

Code letters FVX FVZ GFA
Engine 5.0 L - 230 kW 4.2 L - 257 kW 5.0 L - 230 kW
Turbo-Diesel Turbo-Diesel

Code letters GFB GLZ
Engine 3.2 L -162 kW 3.2L - 177 5.0 L - 230 kW Turbo-
kW Diesel
Gear ratio: Z 1 : Z 2 Final drive 41 : 9 = 4.556 36 : 11 = 3.273
Drive shaft flange dia. 114 mm 122 mm
Electromechanical differential lock Without Without

Code letters GMC GMN GNJ
Engine 3.2 L -162 kW 3.2 L 4.2 L -228 kW 4.9 L - 230 kW
-177 kW Turbo-Diesel
Front final drive OAA

Code letters GNL GNM
Engine 3.2 L - 177 kW 4.5 L - 3.2 L -162 kW 3.2 L -177
250 kW kW
Microsoft

REAR FINAL DRIVE IDENTIFICATION
Rear final drive identification
The rear final drive 0AB/0AC is allocated to the automatic transmission 09D.
Location on rear final drive
Location on rear final drive - arrow -.
Fig. 6: Location On Rear Final Drive

Code letters and date of manufacture of rear final drive.
Microsoft
Fig. 7: Code Letters And Date Of Manufacture Of Rear Final Drive

Example FKY 20 08 02
I I I I
I I I I
manufacture
Rear final drive 0AB/0AC

Code letters FKS FKU FKV
Engine 4.2 L -228 kW 3.2 L -162 kW 3.2 L 4.2 L -228 kW
- 177 kW 3.2 L -
206 kW

Code letters FKW FLM
Microsoft

Engine 3.2 L -162 kW 3.2 L -162 kW
Capacities 1.25 liters 1.6 liters
Electromechanical differential lock Without With

Code letters FLN FLP
Engine 4.2 L - 228 kW 3.2 L -162 kW
Electromechanical differential lock With With
Rear final drive 0AB/0AC 0AB/0AC

Code letters FLT FWC FWG
Engine 3.2 L - 177 kW 4.2 5.0 L - 230 kW 4.2 L - 228 kW
L -228 kW Turbo-Diesel
Capacities 1.6 liters 1.25 liters 1.6 liters
Drive shaft flange dia. 118 mm 118 mm 112 mm/118 mm
Electromechanical differential lock With Without With
Rear final drive "FWG" : In conjunction with automatic transmission 09D = drive axle flange dia. 112 mm.

Code letters FWH GFC GFD
Engine 5.0 L - 230 kW 3.2 L -162 kW 5.0 L - 230 kW
Turbo-Diesel Turbo-Diesel
Electromechanical differential lock With Without Without

Code letters GLP
Microsoft
Application Model Touareg 2004 -->

Engine 3.2 L -162 kW 3.2 L -177 kW
Gear ratio: Z 2 : Z 1 Final drive 39 : 10 = 3.900
Drive shaft flange dia. 112 mm
Electromechanical differential lock Without

Code letters GLQ GLR GLS
Engine 4.2 L -228 kW 3.2 L -162 kW 3.2 L 5.0 L - 230 kW
-177 kW Turbo-Diesel

Code letters GMP GMQ
Engine 4.2 L -228 kW 4.2 L -228 kW

Code letters GNN HLQ
Diesel Diesel

Code letters HLU HLV
Engine 3.2 L -177 kW 4.2 L -228 3.2 L -162 kW 3.2 L -177
Microsoft
kW kW

Code letters FLA GLV
Engine 3.2 L -177 kW 3.2 L -177 kW

Code letters FLA JAJ GLV
Engine 3.2L - 177 kW 5.0 L - 230 kW 3.2L - 177 kW
Turbo-Diesel
Driveshaft flange dia. 112 mm 114 mm 112 mm
Electromechanical differential lock Without With Without

Code letters JLP JLQ
Diesel Diesel
Driveshaft flange 118 mm 118 mm

Code letters JLP JLQ
Diesel Diesel
Microsoft

Driveshaft flange dia. 118 mm 118 mm

Code letters HEX JMB
Engine 3.2 L -177 kW 4.2 L -257 kW
Driveshaft flange dia. 118 mm 118 mm
GENERAL REPAIR INSTRUCTIONS
General repair instructions
To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of
good and proper tools are essential. The usual basic safety precautions also, apply when carrying out vehicle
repairs.
A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned
at various points in the article, are summarized here under the topic "Components" --> Components. They
apply to this article.
Components
Transmission
 When installing the transfer case, make sure that the alignment sleeves between the transmission and
transfer case are correctly positioned.
 When assembling mounting brackets as well as other waxed components the contacts surfaces must be
cleaned. Contact surfaces must be free of grease and wax.
 When exchanging a transfer case, the gear oil must be filled up to lower edge of filler hole.
 Capacities in transfer case --> Code letters, transmission allocation, gear ratios, capacities.
 When exchanging a front final drive, the gear oil must be filled up to lower edge of filler hole.
 Capacities in front final drive --> Code letters, transmission allocation, gear ratios, capacities.
 When exchanging a rear final drive, the gear oil must be filled up to lower edge of filler hole.
 Capacities in rear final drive --> Code letters, transmission allocation, gear ratios, capacities.
Microsoft
Gaskets, seals
 Replace O-rings.
 Radial shaft seals.
Before installing:
Fig. 8: Identifying Space Between Oil Seal Sealing Lips

Lightly lubricate outer edge and fill space between sealing lips - arrow - halfway with grease G 052 128 A1 .
After installation:
 Check gear oil level in transfer case --> Gear oil level in transfer case, checking.
 Check gear oil level in front final drive --> Gear oil in front final drive, checking.
 Check gear oil level in rear final drive --> Gear oil in rear final drive, checking.
Locking elements
 Replace circlip.
 Do not overstretch circlips.
 Circlips must be properly seated in the base of the groove.
Bolts and nuts
 Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
 The tightening torques stated apply to unoiled bolts and nuts.
 Replace self-locking bolts and nuts.
 Make sure with bolted connections that the contact surfaces as well as the visible surfaces of nuts and
bolts are rewaxed after assembly, if necessary.
 Use a thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts
are to be installed. Otherwise there is a risk that the bolts will shear the next time they are removed.
Microsoft
Bearings
 Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the
drift.
Guided fault finding, On Board Diagnostic (OBD) and measuring technology
Fig. 9: VAS 5051 Vehicle Diagnosis, Testing and Information System

 Before replacing the differential motor V253 of the transfer case and, on vehicles with differential lock on
rear final drive, the differential lock motor V304 , the cause of the damage can likely be determined using
the vehicle diagnostic, testing and information system VAS 5051 in the operating mode "Guided Fault-
finding" , "On Board Diagnostics" and "Measuring technology".
34 CONTROLS, HOUSING
ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLED LOCATIONS FOR TRANSFER
CASE
Electrical/electronic components and installed locations for transfer case
Microsoft
Fig. 10: Electrical/Electronic Components And Installed Locations For Transfer Case
1 - Differential control module J646
 Location --> Location of Differential control module J646

 Removing and installing --> Differential control module J646 , removing and installing
2 - Transfer case operating unit E473
 Location --> Location of transfer case operating unit E473

 Removing and installing --> Location of transfer case operating unit E473
3 - Differential motor V253
 Removing and installing --> Differential motor V253 , removing and installing
Microsoft
 The following components are integrated into the differential motor V253 :
 Differential position sensor G398

 Differential position sensor 2 G482
 Motor temperature sensor G407
 Brake for locking motor
4 - Data Link Connector (DLC)
 Installed location --> Data Link Connector (DLC)
5 - Closed throttle position (CTP) switch F60
 Only installed on vehicles with manual transmission

 Installed location --> Location of closed throttle position (CTP) switch F60
 Removing and installing --> Location of closed throttle position (CTP) switch F60
6 - Multi-function display in instrument cluster
 Indicates condition and information about longitudinal lock and off-road gearing in transfer case
Location of Differential control module J646
Fig. 11: Location Of Differential Control Module J646

The differential control module J646 is located under the right front seat - arrow B -.
Differential control module J646 , removing and installing --> Differential control module J646 , removing
and installing.
Location of transfer case operating unit E473
Microsoft
Fig. 12: Location Of Transfer Case Operating Unit E473

The transfer case operating unit E473 - 1 - is located in shift cover - 2 - of center console.
Transfer case operating unit E473 , removing and installing --> 70 - INTERIOR TRIM .
Data Link Connector (DLC)
Fig. 13: Data Link Connector (DLC)

The Data Link Connector (DLC) is located in the cover of the drivers side footwell.
Location of closed throttle position (CTP) switch F60
Microsoft
Fig. 14: Location Of Closed Throttle Position (CTP) Switch F60

The closed throttle position (CTP) switch F60 - 1 - is located in the area of the shift cover with switching
rockers on the manual transmission - 2 -.
Differential control module J646 , removing and installing
Removing
 Remove right front seat --> 72 - SEAT - FRAMES .

 If equipped, remove cover from seat frame.
 First check whether a coded radio is installed. If this is the case obtain the anti-theft coding.
 Switch ignition and all electrical consumers off, and remove ignition key.
 Disconnect Ground (GND) terminal connector from battery --> 27 - BATTERY, STARTER,
GENERATOR, CRUISE CONTROL .
Fig. 15: Separating Connector At Differential Control Module J646 And Connector At Transmission
Control Module J217
 Separate connector - 1 - at differential control module J646 and, if equipped, connector - 2 - at

Microsoft
transmission control module J217.

 Remove bolt - 3 -.
 Pull the retainer with differential control module J646 in direction of - arrow - out of bracket on seat
frame.
Fig. 16: Pressing Retaining Tabs And Pulling Differential Control Module J646 Out Of Retainer
 Press retaining tabs - 1 - in direction of - arrow - and pull differential control module J646 out of retainer.
Make sure that the differential control module J646 does not fall to floor.
Installing
Installation in reverse order of removal. Note the following:
Fig. 17: Pushing Retainer For Differential Control Module J646 With Latches Into Recesses Of Seat
Frame
 Push retainer for differential control module J646 with latches - 2 - into recesses - 1 - of seat frame.
 Fasten bolt - 3 - to 8 Nm.
 Connect Ground (GND) terminal connector to battery and perform work sequences after connecting
battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
Microsoft
DIFFERENTIAL, REMOVING AND INSTALLING
Differential, removing and installing
Fig. 18: Identifying Special Tools - Differential, Removing And Installing (1 Of 2)

Special tools, testers and auxiliary items required
 Transmission support VW 785/1B

 Adapter 10 - 222 A/7
 Lifting tackle 2024 A
 Thrust pad 3062
 Transmission support 3282
Microsoft
 Adjustment plate 3282/37
Fig. 19: Identifying Special Tools - Differential, Removing And Installing (2 Of 2)

 Torque wrench V.A.G 1331

 Engine/transmission jack V.A.G 1383/A
 Grease for clutch disc shaft splines G 000 100
Transfer case, removing
 Raise vehicle.
Microsoft
 Remove sound insulation on bottom of transmission.

 If an underbody impact guard is located beneath the transfer case, remove it --> 50 - BODY - FRONT .
 Remove rear section of exhaust system and, if necessary, catalytic converters (V10 TDI) -->
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL,
FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE
MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
 Remove rear driveshaft --> Rear driveshaft, removing and installing.

 Remove bolts for front driveshaft at front final drive and at transfer case.
Fig. 20: Removing Damper From Transfer Case

 If equipped with damper - A - , remove damper from transfer case (bolts - B -).
Before removing, mark the installation position of damper relative to transfer case. The text "TOP" -
arrow - must point upward.
 Set up engine/transmission jack V.A.G 1383/A with transmission support 3282 , adjustment plate
3282/37 for "0AD" transmission and support elements as follows:
 Place adjustment plate 3282/37 on transmission support 3282 (adjustment plate only fits in one position).
 Align arms of transmission support according to holes in adjustment plate.
The symbols on adjusting plate indicate the support elements required. The arrow points forward.
Microsoft
Fig. 21: Securing Transmission On Transmission Support 3282 Using Bolt & Removing Transmission
Support From Structure
 Move engine/transmission jack V.A.G 1383/A with transmission support 3282 under transmission, align
adjustment plate parallel to transmission and support transmission.
 Secure transmission on transmission support 3282 using bolt - A -.
 Remove transmission support - B - from structure.
 Unbolt transmission support from transfer case console - arrows -.
 Remove front driveshaft.

 Remove side and lower transmission/transfer case bolts.
Fig. 22: Disconnecting Connector From Differential Motor

 Disconnect connector - A - and - B - from differential motor.

 Lower engine and transmission assembly about 60 mm using engine/transmission jack V.A.G 1383/A.
Microsoft
Fig. 23: Securing Engine And Transmission Assembly On Structure With Transmission Support VW
785/1B
 Secure engine and transmission assembly on structure - arrows - with transmission support VW 785/1B
as follows:
 Lubricate contact surface of thrust pad of VW 785/1B with multi-purpose grease .
 Place thrust plate 3062 on thrust pad. The smaller diameter of thrust plate 3062 faces toward thrust pad.
 Place a piece of wood - A - between transmission and thrust pad 3062.
Fig. 24: Removing Upper Transfer Case/Transmission Bolts & Uncliping Breather Line From Transfer
Case
 Remove upper transfer case/transmission bolts - A -.

 Remove - arrow 1 - and unclip - arrow 2 - breather line - B - from transfer case.
 Press transfer case off from transmission.
Microsoft
Fig. 25: Lowering Transfer Case

 Lower transfer case.
Transfer case, transporting
Fig. 26: Attaching Engine Sling 2024A As Follows To Lifting Eyes Of Transfer Case And Transport With
Workshop Crane
 Attach engine sling 2024A as follows to lifting eyes of transfer case and transport with workshop crane.
Input shaft side:
 4. Hole for hook in position 1 of engine sling - arrow A -.
Output shaft side (driveshaft flange):
 2. Hole for hook rail in position 8 of engine sling - arrow B -.
CAUTION: The hooks and locating pins must be secured with locking pins.
Microsoft
Transfer case, installing
Install in reverse order, paying attention to the following:
 Check if alignment sleeves for centering the transmission/transfer case are installed in transmission;
install if necessary.
Always replace O-ring seal between transfer case and transmission - arrow -. Lubricate lightly.
Fig. 27: Identifying O-Ring Seal Between Transfer Case And Transmission
Lubricate transfer case input shaft and transmission output shaft with grease for clutch disc shaft splines
G 000 100.
Push transfer case completely onto transmission, ensuring that transfer case input shaft splines are
centered as they are guided onto transmission output shaft.
If splines are correctly positioned and centrally aligned, the transfer case will slide to stop against
transmission.
Do not use bolts to pull transfer case onto the transmission, otherwise transfer case will be distorted.
 Install front driveshaft --> Front driveshaft, removing and installing.
Microsoft
Fig. 28: Removing/Installing Damper From/To Transfer Case

 If equipped, install damper - A - to transfer case and fasten bolts - B -.
The text "TOP" - arrow - must point upward.
 Install rear driveshaft --> Rear driveshaft, removing and installing.

 If an underbody impact guard is located beneath the transfer case, install it --> 50 - BODY - FRONT .
 Install exhaust system -->
.
Tightening torques
Transfer case to transmission 45 Nm

Damper to transfer case 32 Nm
Console to transfer case, console to transmission and transmission support to structure.
Routing of breather line on transfer case
Microsoft
Fig. 29: Routing Of Breather Line On Transfer Case

The breather line - 1 - for the transfer case runs over the transfer case and manual transmission to coolant hose -
4 -.
The breather line is clipped into the retainer - 2 - on the transfer case and retainer - 3 - on the manual
transmission.
The illustration shows routing of the line with a manual transmission. The routing of the line with an automatic
transmission is similar.
TRANSMISSION CARRIER AND CONSOLE, REMOVING AND INSTALLING
Transmission carrier and console, removing and installing
Microsoft
Fig. 30: Identifying Special Tools - Transmission Carrier And Console, Removing And Installing

 Engine/transmission jack V.A.G 1383 A with universal transmission adapter V.A.G 1359/2
Transmission carrier and console, removing
 Raise vehicle.
 Remove sound insulation below transmission.
 If an underbody impact guard is located beneath transmission carrier and console, remove it --> 50 -
BODY - FRONT .
Microsoft
Fig. 31: Removing Bolts For Transmission Support From Transfer Case Console
 Place engine/transmission jack V.A.G 1383 A with universal adapter V.A.G 1359/2 and a block of wood
- A - under transfer case.
Do not loosen bolts - arrows - yet.
Fig. 32: Unbolting/Tightening Transmission Carrier From/To Structure

 Unbolt transmission carrier - A - from structure - arrows -.

 Lower transfer case slightly, until transmission carrier hangs freely.
Microsoft
 Remove bolts for transmission support from transfer case console - arrows -.
Fig. 34: Unbolting Console From Transfer Case

 Unbolt console - A - from transfer case - arrows -.
Transmission carrier and console, installing
Install is performed in the reverse order of removal.
Tightening torques
Console to transmission carrier 50 Nm plus an additional 90° (1 /4 turn
 Always replace bolts
Due to the various engine variations and differing lengths of the transfer case extension, there are various
consoles and transmission carriers. Allocation depends on the engine installed .
The various options result in the following fastening points for console to transfer case and transmission carrier
Microsoft
to structure:
Vehicles with 6 and 8-cylinder engine.
Fig. 35: Identifying Fastening Points For Console To Transfer Case And Transmission Carrier To
Structure (Vehicles With 6 And 8-Cylinder Engine)
Console to transmission carrier
Console to transfer case

Bolts - 1 - M8 x 35 20 Nm
Bolts - 2 - M8 x 70 20 Nm
Transmission carrier to structure

Bolts - 3 - M10 x 80 * See note 50 Nm plus an additional 90° 1 /4 turn
*Always replace bolts
Vehicles 10-cylinder engine
Microsoft
Fig. 36: Identifying Fastening Points For Console To Transfer Case And Transmission Carrier To
Structure (Vehicles 10-Cylinder Engine)
Console to transmission carrier
Console to transfer case

Bolts - 1 - M8 x 35 20 Nm
Bolts - 2 - M8 x 70 20 Nm
Transmission carrier to structure

Bolts - 3 - M10 x 80 50 Nm plus an additional 90° 1 /4 turn
 If an underbody impact guard is located beneath transmission carrier and console, install it --> 50 -
BODY - FRONT .
BONDED RUBBER BUSHING IN TRANSMISSION CARRIER, REPLACING
Bonded rubber bushing in transmission carrier, replacing
Microsoft
Fig. 37: Identifying Special Tools - Bonded Rubber Bushing In Transmission Carrier, Replacing
 Pressure plate VW 402

 Punch VW 412
 Thrust plate VW 432
 Base block VW 441
 Tube 3296
 Alignment fixture T10214
 Remove transmission carrier --> Transmission carrier and console, removing and installing.
Microsoft
Fig. 38: Pressing Out Bonded Rubber Bushing

 Pressing out bonded rubber bushing.
Fig. 39: Pressing New Bonded Rubber Bushing With Pressure Piece T10214/3 Into Guide Sleeve
T10214/2 , Until Pressure Piece T10214/3 Is Flush With Guide Sleeve T10214/2
 Connect new bonded rubber bushing with pressure piece T10214/3.

 Press new bonded rubber bushing - A - with pressure piece T10214/3 into guide sleeve T10214/2 , until
pressure piece T10214/3 is flush with guide sleeve T10214/2.
Microsoft
Fig. 40: Aligning Bonded Rubber Bushing To Transmission Carrier, Using Assembly Tool T10214
 Align bonded rubber bushing to transmission carrier, using assembly tool T10214.
 To align bushing, align bolts - A - and/or notch - arrow - on pressure piece T10214/3 centrally to holes in
transmission carrier.
Spacing "x" must be equal.
Fig. 41: Pressing Bonded Rubber Bushing Into Transmission Carrier, Until Guide Sleeve T10214/2 Can
Be Turned By Hand
 Press bonded rubber bushing into transmission carrier, until guide sleeve T10214/2 can be turned by hand
- arrows -.
Do not press the bonded rubber bushing any deeper into the transmission carrier than the height of the
tube 3296. If necessary press further with base block VW 441 up to stop.
 Install transmission carrier --> Transmission carrier and console, removing and installing.
GEAR OIL LEVEL IN TRANSFER CASE, CHECKING
Microsoft
Gear oil level in transfer case, checking
Transmission oil specification --> Code letters, transmission allocation, gear ratios, capacities
Fig. 42: Torque Wrench V.A.G 1331

Fig. 43: Removing Sealing Plug For Gear Oil Inspection

 Remove sealing plug for gear oil inspection - arrow -.
Oil level is correct when the transfer case is filled up to lower edge of oil filler hole.
 Insert new plug - arrow - and fasten.
When initially filling transfer case:
 Remove plug - arrow -.
Microsoft
 Top off oil to lower edge of filler hole.

 Insert new plug - arrow - and fasten.
Tightening torque:
Oil filler plug 20 Nm
SEALS FOR OUTPUT FLANGE/DRIVESHAFT AND DIFFERENTIAL MOTOR , REMOVING AND

INSTALLING
Seals for output flange/driveshaft and differential motor , removing and installing
Fig. 44: Identifying Special Tools - Seals For Output Flange/Driveshaft And Differential Motor ,
Removing And Installing (1 Of 3)

Microsoft
 Holding fixture VW 313

 Punch VW 408 A
 Holding fixture VW 540
 Slide hammer VW 771

 Pulling hook VW 771/37
 Thrust pad 30 - 504

Microsoft
 Tube 32 - 119
 Thrust pad 3062

 - 3 - - Kukko 17/2 Separating device
 Thrust plate T10185

Microsoft
 Socket T10204
 Wiring harness repair kit VAS 1978
 Loctite 648
Tension transfer case in assembly fixture --> Secure transfer case to assembly stand with bolts
Fig. 47: Seals For Output Flange/Driveshaft And Differential Motor Remove/Install Components
1 - Nut, 130 Nm
 Always replace
 Removing --> Fig. 71
 Installing --> Fig. 75
Microsoft
 Securing --> Fig. 69
 Insert with Loctite 648
2 - O-ring
 Always replace
 Insert with gear oil --> Fig. 74
3 - Output flange
 For rear driveshaft

 Removing and installing --> Output flange oil seal for rear driveshaft, replacing (transfer case
installed)
4 - Dust plate
 For output flange

 Pressing off --> Pressing off dust plate
 Pressing on --> Pressing on dust plate to stop
5 - Seal
 For output flange/rear driveshaft

 Pulling out --> Pulling out oil seal for output flange/rear driveshaft
 Driving in --> Driving in oil seal for output flange/rear driveshaft
 Replacing with transmission installed --> Output flange oil seal for rear driveshaft, replacing
(transfer case installed)
6 - Breather pipe
 Removing Remove breather tube

 Driving in --> Driving in breather tube
7 - Input shaft oil seal
 Removing and installing --> Input shaft seal, replacing
8 - O-ring
 Always replace
 Insert into groove of input shaft --> Insert into O-ring into groove of input shaft
9 - Nut, 130 Nm
Microsoft
 Always replace
 Removing --> Fig. 65
 Installing --> Fig. 68
 Securing --> Fig. 69
 Insert with Loctite 648
10 - O-ring
 Always replace
 Insert with gear oil --> Fig. 74
11 - Output flange
 For front driveshaft

 Removing and installing --> Output flange oil seal for front driveshaft, replacing (transfer case
installed)
12 - Dust plate
 For output flange

 Pressing off --> Pressing off dust plate
 Pressing on --> Pressing on dust plate to stop
13 - Seal
 For output flange/front driveshaft

 Pulling out --> Pulling out oil seal for output flange/rear driveshaft
 Driving in --> Driving in oil seal for output flange/front driveshaft
 Replacing with transmission installed --> Output flange oil seal for front driveshaft, replacing
(transfer case installed)
14 - O-ring
 Must rest in groove of Differential Motor V253
15 - Alignment bushing
 Qty. 2
 For aligning differential motor on transfer case
16 - Differential motor V253
 Removing and installing --> Differential motor V253 , removing and installing
Microsoft
 The following components are integrated into differential motor : Differential position sensor G398 ,
differential position sensor 2 G482 , Motor temperature sensor G407 , Brake for locking motor and Oil
Temperature Sensor G8
 Differential motor and integrated components can be tested with "Guided fault-finding"
17 - Bolt, 27 Nm
18 - Bolt, 14 Nm
19 - Clamp
 For fastening differential motor V253 on transfer case

 No longer available as separate part as of 02.05
20 - Oil drain plug, 20 Nm
 Always replace
21 - Bolt, 20 Nm
22 - Bolt, 20 Nm
23 - Console
 Removing and installing --> Transmission carrier and console, removing and installing
24 - Engine oil temperature sensor G8 , 17 Nm
 On certain transmissions, a sealing plug may also be installed --> Repair solution for replacement of
Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8
 The discontinuation of engine oil temperature sensor occurred shortly after start of production. Transfer
cases were introduced that were no longer equipped with a hole in the housing for the engine oil
temperature sensor.
 Repair solution for faulty engine oil temperature sensor --> Repair solution for replacement of
Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8
25 - Seal
 Always replace
26 - Oil filler plug, 20 Nm
 Always replace
27 - Bolt, 32 Nm
Microsoft
28 - Vibration damper
 Not in all transmissions

 Observe installed location --> Fig. 28
29 - Transfer case
Secure transfer case to assembly stand with bolts
Fig. 48: Securing Transfer Case To Assembly Stand With Bolts

Pressing off dust plate
Fig. 49: Pressing Off Dust Plate

A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing on dust plate to stop
Microsoft
Fig. 50: Pressing On Dust Plate To Stop

Pulling out oil seal for output flange/rear driveshaft
Fig. 51: Pulling Out Sealing Ring Using Slide Hammer-Complete Set VW 771 And Additional Part For
VW 771 VW 771/37
 Figure shows seal for output flange/rear driveshaft being pulled out.
 The procedure for pulling out oil seal for output flange/front driveshaft is identical.
Driving in oil seal for output flange/rear driveshaft
Microsoft
Fig. 52: Driving In Oil Seal For Output Flange/Rear Driveshaft

 Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Insert into O-ring into groove of input shaft
Fig. 53: Identifying O-Ring Seal Between Transfer Case And Transmission
Pressing on dust plate to stop
Microsoft
Fig. 54: Pressing On Dust Plate To Stop

Driving in oil seal for output flange/front driveshaft
Fig. 55: Driving New Seal In As Far As Stop

Remove breather tube
Fig. 56: Removing Breather Tube

 Guide 5 mm diameter drift - B - into hole of breather pipe.

 Move breather pipe - A - in direction of arrow while simultaneously prying breather tube out of transfer
case using screwdriver - C -.
Driving in breather tube
Microsoft
Fig. 57: Driving In Breather Tube

 Coat breather tube with locking fluid Loctite 648 before driving in.
Repair solution for replacement of Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8
Fig. 58: Repairing Solution For Replacement Of Differential Motor V253 And For Malfunctioning Oil
Temperature Sensor G8
When replacing Differential Motor V253 and when Oil Temperature Sensor - 4 - is malfunctioning, the Oil
Temperature Sensor (with sealing ring - 3 -) is replaced by a screw plug - 1 - with sealing ring - 2 -.
Microsoft
Fig. 59: Removing Wiring Harness For Engine Oil Temperature Sensor G8
Furthermore, the wiring harness for engine oil temperature sensor G8 is removed as follows:
 Remove bolts - arrows - and remove retainer - 1 - for differential motor connector.
 Pivot 10-pin connector out of retainer - 2 -.
Fig. 60: Identifying Engine Oil Temperature Sensor Wiring Harness & 10-Pin Connector
 The wires, pins - 1 - and - 2 - of 10-pin connector must be removed using appropriate ejection tool from
wiring harness repair kit VAS 1978.
 Remove wiring harness - 3 - for engine oil temperature sensor.
 Close off wire openings of terminals - 1 - and - 2 - in 10-pin connector .
Input shaft seal, replacing
Microsoft
Fig. 61: Identifying Special Tools - Input Shaft Seal, Replacing

 Puller T10055
 Adapter T10055/2
 Sealing grease G 052 128 A1
 Sheet metal screw approx. 4 mm diameter
Removing
 Remove transfer case --> Transfer case, removing.
Microsoft
Fig. 62: Screwing Sheet Metal Screw Into Seal

 To pull out seal, screw a sheet metal screw of approx. 4 mm diameter into seal - arrow -.
Thread in sheet metal screw in so that it jams between seal lip and metal ledge of sealing ring.
Do not screw in sheet metal screw too far to avoid damaging bearing behind it.
 Pull out seal using puller T10055.
Installing

 Drive new seal in as far as stop; be sure not to distort seal.

 Install transfer case --> Transfer case, installing.
Output flange oil seal for front driveshaft, replacing (transfer case installed)
Microsoft
Fig. 64: Identifying Special Tools - Output Flange Oil Seal For Front Driveshaft, Replacing (Transfer
Case Installed)

 Handle-Hold Dr. Shaft Flange 3145

 Socket T10204
 Loctite 648
Microsoft
 2 Bolts M10 x 25
Removing
 Remove front driveshaft --> Front driveshaft, removing and installing.
Fig. 65: Securing Handle-Hold Dr. Shaft Flange 3145 With Bolts To Output Flange
 Secure Handle-Hold Dr. Shaft Flange 3145 with 2 bolts M10 x 25 to output flange - arrows -.
 Unscrew nut for output flange.
 Remove output flange.
 Pull out sealing ring using slide hammer-complete set VW 771 and additional part for VW 771 VW
771/37.
 Clean threads of nut.
Installing

Microsoft

 Insert output flange.
Fig. 67: Moistening New O-Ring With Gear Oil And Insert
 Moisten new O-ring - arrow - with gear oil and insert.

 Coat threads of new nut with locking fluid Loctite 648 .
Fig. 68: Tightening New Nut For Output Flange

 Tighten new nut for output flange to torque specification.
Microsoft
Fig. 69: Securing Nut At Intended Points

 Secure nut at intended points - arrows - (e.g., using a drift).
The illustration shows securing the nut on output flange/rear driveshaft.
 Install front driveshaft --> Front driveshaft, removing and installing.

Tightening torque
Nut for output flange on output shaft 130 Nm
 Always replace nuts
Output flange oil seal for rear driveshaft, replacing (transfer case installed)
Microsoft
Fig. 70: Identifying Special Tools - Output Flange Oil Seal For Rear Driveshaft, Replacing (Transfer
Case Installed)

 Handle-Hold Dr. Shaft Flange 3145

 Socket T10204
 Loctite 648
Microsoft
 2 Bolts M10 x 25
Removing
Fig. 71: Unscrewing Nut For Output Flange

 Unscrew nut for output flange.
A - Bolts M10 x 30 with nuts
 Remove output flange.
Fig. 72: Pulling Out Sealing Ring Using Slide Hammer-Complete Set VW 771 And Additional Part For
VW 771 VW 771/37
771/37.
 Clean threads of nut.
Microsoft
Installing
 Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

 Drive new seal in as far as the stop; be sure not to distort seal.
 Insert output flange.
Fig. 74: Moistening New O-Ring With Gear Oil And Insert
 Moisten new O-ring - arrow - with gear oil and insert.
The figure shows the O-ring on output flange/front driveshaft.
 Coat threads of new nut with locking fluid Loctite 648.
Microsoft
Fig. 75: Unscrewing/Tightening Nut For Output Flange

 Tighten new nut for output flange to torque specification.
Fig. 76: Securing Nut At Intended Points

 Secure nut at intended points - arrows - (e.g., with a drift).

Tightening torque
Nut for output flange on output shaft 130 Nm
 Always replace nut
DIFFERENTIAL MOTOR V253 , REMOVING AND INSTALLING
Differential motor V253 , removing and installing
Microsoft

Differential motor V253 , removing
If Differential Motor V253 is replaced, observe the following:
The new Differential Motor is set to a specified position.
 To make installation easier, set this position on differential as well, if possible:
Fig. 78: Rotating Transfer Case Operating Unit E473 To "LOW" Position
 To do this, switch ignition on.

 Rotate Transfer Case Operating Unit E473 to "LOW" position - arrow -.
Microsoft
 Then switch ignition off.
If previous Differential Motor will be reinstalled, Transfer Case Operating Unit E473 does not need to be
set to the "LOW" position.
Continued for all
 If shield is installed over differential motor , remove it.
Fig. 79: Installing Bracket & Connecting Connectors

 Separate connectors - A - , - B - and - C -.

 Remove bracket - D - - arrows -.
Fig. 80: Removing Bolts And Differential Motor From Transfer Case
Microsoft
 Remove bolts - arrows - and remove differential motor from transfer case.
Differential motor V253 , installing
If a new Differential Motor is installed, observe the following:
Transfer Case Operating Unit E473 was already  Transfer Case Operating Unit setting --> (Fig.
turned to "LOW" position with ignition on. 1)
Transfer Case Operating Unit E473 was not turned  Transfer Case Operating Unit setting --> (Fig.
to "LOW" position. 2)
(Fig. 1)
Fig. 81: Identifying Transfer Case Operating Unit E473 Is In "LOW" Position
 The Transfer Case Operating Unit E473 is in "LOW" position.

 Shaft with interrupted tooth pattern - 1 - must be in - a - position.
" a = approx. 10° "

Microsoft
 If necessary, set the interrupted tooth pattern - 1 - on shaft of differential motor to position shown in the
illustration (e.g. using a screwdriver).
(Fig. 2)
Fig. 82: Identifying Transfer Case Operating Unit E473 Is Not In "LOW" Position
 The Transfer Case Operating Unit E473 is not in "LOW" position.

 Shaft with interrupted tooth pattern - 1 - must be in - a - position.
" a = approx. 60° "
 If necessary, set the interrupted tooth pattern - 1 - on shaft of differential motor to the position shown in
the illustration (e.g. using a screwdriver).
Continued for all
 Make sure that O-ring that seals on transfer case makes contact in base of groove at the differential motor.
 Set differential motor on alignment sleeves - 2 - of transfer case.
 Ensure that the interrupted teeth on differential motor - arrow A - and on selector shaft/transfer case -
arrow B - are aligned.
Microsoft
Fig. 83: Removing/Installing Bolts And Differential Motor From Transfer Case
 Insert bolts - arrows - for differential motor and fasten.
Fig. 84: Installing Bracket & Connecting Connectors

 Install bracket - D - - arrows -.

 Connect connectors - A - , - B - and - C -.
 If shield was fitted over differential motor , install it.
Tightening torque
Differential motor to transfer case 27 Nm
Bracket for transfer case 14 Nm
Microsoft
39 FINAL DRIVE, DRIVESHAFTS

DRIVESHAFTS, REMOVING AND INSTALLING
Assembly overview
Front driveshaft, removing and installing --> Front driveshaft, removing and installing.
Rear driveshaft, removing and installing --> Rear driveshaft, removing and installing.
 No repairs may be performed on the driveshafts.

 Do not flex rear driveshaft; store and transport extended.
 Store rear driveshaft with bracket facing upward.
 Before removing, mark the positions of all parts in relation to each other. Re-install in the same position
otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises.
 If front or rear driveshaft is disconnected only from transfer case or only from its respective final drive, it
must be tied up or supported.
 In customer complaints arise (noises, vibration) regarding the front or rear driveshaft, turn respective
driveshaft on the final drive the distance of one bolt hole before bolting on again. This procedure can be
repeated 5 times on the final drives and twice on back of transfer case.
Microsoft
Fig. 85: Driveshafts Assembly Overview

1 - Front final drive
 Colored markings on driveshaft flange and on front driveshaft must line up.
2 - Lock plate
3 - Bolt, 30 Nm plus an additional 90° 1 /4 turn
 Always replace
4 - Front driveshaft
 Installation position: Colored spot on front driveshaft must line up with colored spot on front final drive
Microsoft
5 - Transfer case
6 - Nut
 Always replace
7 - Flexible disc
 Removing and installing --> Flexible disc, removing and installing
8 - Washer
9 - Bolt, 75 Nm
10 - Rear driveshaft
 Installation position: Colored spot on rear driveshaft must line up with colored spot on rear final drive
 To avoid damaging boot in vicinity of center bearing - arrow - , rear driveshaft may only be flexed
slightly
11 - Multi-point socket head bolt, 30 Nm plus an additional 90° 1 /4 turn
 Always replace
12 - Lock plate
13 - Rear final drive
14 - Bracket
 For center bearing
15 - Bolt, 20 Nm
 On bracket for rear driveshaft

 To adjust driveshaft center bearing free of tension, loosen and tighten --> Rear driveshaft center
bearing, installing stress-free
16 - Bolt, 60 Nm
 Bracket to body
17 - Bolt
18 - Hex nut, 75 Nm
Microsoft
 Always replace
Front driveshaft, removing and installing
Fig. 86: Identifying Special Tools - Front Driveshaft, Removing And Installing

 Engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2
 Brake pedal loading device V.A.G 1869/2
A twin-post vehicle hoist should be used when working on the front driveshaft.
Microsoft
Before removing, mark the positions of all parts in relation to each other. Re-install in the same position
If droning noises occur when driving, unbolt front driveshaft from flange at front final drive, rotate one
hole relative to flange and bolt on again.
If droning noises are still audible, the front driveshaft can be rotated one hole relative to flange a total of
5 times.
Removing
 For vehicles with automatic transmission, select position "N" with selector lever.
 Insert brake pedal depressor V.A.G 1869/2.
 Raise vehicle.
 Remove sound insulation on bottom of transmission.
 If an underbody impact guard is located beneath the driveshaft, remove it --> 50 - BODY - FRONT .
Fig. 87: Identifying Mark On Driveshaft Flange & Front Final Drive
 Check whether there is a colored marking on front driveshaft and at driveshaft flange at front final drive.
 If this marking is not present, then mark in color the position of driveshaft flange - arrow A - to front
final drive - arrow B -.
Microsoft
Fig. 88: Removing Lower Three Bolts From Front Driveshaft At Front Final Drive
 Remove lower three bolts from front driveshaft at front final drive - arrows A -.
Fig. 89: Removing Lower Three Bolts From Front Driveshaft At Output Flange Of Transfer Case
 Remove lower three bolts from front driveshaft at output flange of transfer case - arrows B -.
 Lower vehicle.
 Remove brake pedal depressor V.A.G 1869/2.
 Raise vehicle.
 Rotate both front wheels in same direction at same time so that the front driveshaft rotates 1 /2 turn
(180°).
 Lower vehicle.
 Raise vehicle.
 Remove remaining three bolts from front driveshaft at front final drive and at transfer case.
Microsoft
Fig. 90: Placing Engine/Transmission Jack V.A.G 1383 A With Universal Adapter 1359/2 And Block Of
Wood Under Transfer Case
Remove transmission carrier as follows:
 Place engine/transmission jack V.A.G 1383 A with universal adapter 1359/2 and a block of wood - A -
under transfer case.
Do not loosen bolts - arrows - yet.

 Unbolt transmission carrier - A - from structure - arrows -.
Microsoft
 Remove bolt for transmission carrier from transfer case console - arrows -.
 Remove front driveshaft.
If the front driveshaft cannot be removed, lower the engine/transmission assembly slightly. When doing
this, the engine must not come to rest against the bulkhead.
Installing
Installation is in reverse order of removal. Note the following:
Fig. 93: Identifying Mark On Driveshaft Flange & Front Final Drive
Always replace bolts for front driveshaft.
 Markings - arrow A - and - arrow B - must line up as much as possible.
Microsoft
Install transmission carrier as follows:
 Use new bolts.

 First tighten the transmission carrier to the transfer case console - arrows - to tightening torque.

 Then, tighten the transmission carrier - A - to the body - arrows - to tightening torque --> Tightening
torques.
 Insert bolts for front driveshaft and tighten to tightening torque --> Tightening torques
 If an underbody impact guard is located beneath the driveshaft, install it --> 50 - BODY - FRONT .
Tightening torques
Console to transmission carrier 50 Nm plus an additional 90° 1 /4 turn
Always replace bolts

Transmission carrier to structure 50 Nm plus an additional 90° 1 /4 turn
Microsoft

Front driveshaft to front final drive flange 30 Nm plus an additional 90° 1 /4 turn

Front driveshaft to transfer case flange 30 Nm plus an additional 90° 1 /4 turn
Rear driveshaft, removing and installing
Fig. 96: Identifying Special Tools - Rear Driveshaft, Removing And Installing

Microsoft

A twin-post vehicle hoist should be used when working on the rear driveshaft.
If droning noises occur when driving, unbolt rear driveshaft from flange at rear final drive, rotate one
hole relative to flange and bolt on again.
If droning noises are still audible, rear driveshaft can be rotated one hole relative to flange a total of 5
times at rear final drive and a total of 2 times at transfer case.
Do not flex rear driveshaft; store only extended with center bearing bracket facing upward.
Removing
 For vehicles with automatic transmission, select position "N" with selector lever.
 Raise vehicle.
 Remove rear part of exhaust system -->
.
 If an underbody impact guard is located beneath the driveshaft, remove it --> 50 - BODY - FRONT .
Microsoft
Fig. 97: Identifying Mark On Driveshaft Flange & Rear Final Drive
 Check whether there is a colored marking on rear driveshaft and on driveshaft flange at rear final drive.
 If marking is not present, mark in color position of driveshaft flange - arrow A - to rear final drive -
arrow B -.
Fig. 98: Marking Position Of Rear Driveshaft To Transfer Case Output Flange
 Mark position of rear driveshaft to transfer case output flange - arrow -.
Microsoft
Fig. 99: Removing Lower Bolts For Rear Driveshaft At Rear Final Drive
 Remove lower 3 bolts for rear driveshaft at rear final drive.

 Lower vehicle.
 Remove brake pedal depressor V.A.G 1869/2.
 Raise vehicle.
 Rotate both rear wheels in same direction at the same time so that the rear driveshaft rotates 1 /2 turn
(180°).
 Lower vehicle.
 Raise vehicle.
 Remove remaining 3 bolts for rear driveshaft at rear final drive.
Fig. 100: Removing Bolts From Rear Driveshaft At Transfer Case

 Remove bolts - arrows - from rear driveshaft at transfer case. For this, counterhold nuts with an open end
wrench.
 Place engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2 under
subframe/rear axle.
Microsoft
Fig. 101: Removing/Installing Both Front Bolts On Subframe

 Support subframe with a wooden block --> Fig. 102.

 Remove both front bolts - arrows - on subframe.
Fig. 102: Lowering Subframe Using Engine/Transmission Jack V.A.G 1383 A

 Lower subframe using engine/transmission jack V.A.G 1383 A by dimension - a - = 50 mm.
1 - Wooden support
To avoid damaging rear driveshaft, have a second technician assist in removing rear driveshaft.
Microsoft
Fig. 103: Loosening Bolts For Center Bearing Bracket & Unbolting Center Bearing Bracket From Body
 Loosen bolts - arrows B - for center bearing bracket by approx. 2 turns.

 Unbolt center bearing bracket from body - arrows A -.
Fig. 104: Pressing Rear Driveshaft Off Of Rear Final Drive And Pivot It Over Final Drive Flange
 Press rear driveshaft - 1 - off of rear final drive - 2 - and pivot it over final drive flange.
 Carefully pull rear driveshaft off from alignment sleeves of output flange/transfer case.
 Remove rear driveshaft.
 Set aside rear driveshaft with center bearing bracket facing upward.
Installing
Microsoft
Always replace bolts for rear driveshaft.
 Markings - arrow A - and - arrow B - must line up as much as possible.
Fig. 106: Identifying Seal In Rear Driveshaft Flange At Flange/Transfer Case Must Not Be Damaged
When Removing/Installing
Seal - arrow - in rear driveshaft flange at flange/transfer case must not be damaged when removing and
installing.
Replace rear driveshaft if damaged.
Do not tip rear driveshaft; push horizontally onto guide shaft.
After loosening a rear driveshaft flange, install center bearing so that it is free of stress --> Rear driveshaft
center bearing, installing stress-free.
Microsoft
Fig. 107: Removing/Installing Both Front Bolts On Subframe

 Install and fasten bolts - arrows - at subframe --> 42 - REAR SUSPENSION

 After installing rear driveshaft, install center bearing so that it is free of stress --> Rear driveshaft center
bearing, installing stress-free.
 Install rear part of exhaust system -->
.
 Insert bolts for rear driveshaft and tighten to specified torque.
 If an underbody impact guard is located beneath the driveshaft, install it --> 50 - BODY - FRONT .
Tightening torques
Rear driveshaft to rear final drive flange 30 Nm plus an additional 90° 1 /4 turn

Rear driveshaft to flexible disc 75 Nm
Center bearing bracket to body 60 Nm
Rear driveshaft center bearing, installing stress-free
Microsoft
 If necessary, remove rear part of exhaust system -->

.
 Remove bolts - arrows B -.

 Loosen bolts - arrows A - several turns.
Fig. 109: Aligning Center Bearing Bracket Centrally To Lateral Stops On Body
Microsoft
 Align center bearing bracket centrally to lateral stops - arrows - on body.

 Fix center bearing bracket in place by fastening the two bolts - A -.
 Check if threaded holes of center bearing - B - are lined up with slots of bracket.
For slight deviations:
 Move center bearing bracket laterally until the threaded holes and slots line up.
When moving bracket, make sure that the center bearing does not touch the body (driveshaft tunnel).
For larger deviations or if clearance between center bearing and body is minimal:

 Loosen bolts - arrows - for transmission carrier by approx. 3 turns.

 Move transmission laterally until threaded holes of center bearing and slots of center bearing bracket line
up.
When moving transmission, make sure that the center bearing does not touch body (driveshaft tunnel).
 Replace individual bolts - arrows - , in succession, for transmission carrier and tighten them to tightening
torque.
Microsoft
 Install bolts - arrows B - and fasten bolts - arrows A - and - arrows B -.

 If removed earlier, install rear part of exhaust system -->
.
Torque specifications
Center bearing bracket to body 60 Nm
Rear driveshaft center bearing to bracket 20 Nm
Transmission carrier to structure 50 Nm plus an additional 90° 1 /4
Flexible disc, removing and installing
Microsoft


Fig. 113: Brake Pedal Depressor V.A.G 1869/2

A twin-post vehicle hoist should be used when working on the rear driveshaft.
Do not flex rear driveshaft; store only extended with center bearing bracket facing upward.
Removing
 For vehicles with automatic transmission, select position "N" with the selector lever.
 Raise vehicle.
Microsoft

.
Fig. 114: Unbolting Flexible Disc From Rear Driveshaft

 Unbolt flexible disc from rear driveshaft - arrows -.
Installing
Microsoft
Fig. 115: Identifying Seal In Rear Driveshaft Flange At Flange/Transfer Case Must Not Be Damaged
When Removing/Installing
Seal - arrow - in rear driveshaft flange at flange/transfer case must not be damaged when removing and
installing.
Replace rear driveshaft if damaged.
Do not tip rear driveshaft; push horizontally onto guide shaft.

 After installing rear driveshaft, install center bearing so that it is free of stress --> Rear driveshaft center
bearing, installing stress-free.
.
Tightening torque
Flexible disc to transfer case flange 75 Nm
 Always replace nut, build torque at the bolt

while counterholding the nut
Microsoft
39F FINAL DRIVE, FRONT DIFFERENTIAL

GEAR OIL IN FRONT FINAL DRIVE, CHECKING


Oil level is correct when the front final drive is filled up to lower edge of oil filler hole.
 Fasten bolt - arrow - with new seal.
When initially filling front final drive

Microsoft
 Remove bolt - arrow -.

Tightening torque
Oil filler plug to front final drive 35 Nm
FRONT FINAL DRIVE, REMOVING AND INSTALLING
Front final drive, removing and installing
Fig. 118: Identifying Special Tools - Front Final Drive, Removing And Installing

Microsoft
 Tensioner hooks VW 552

 Spindle 10 - 222 A/11

 Socket insert T10099/1
Front final drive, removing
 Loosen wheel bolts.

 Raise vehicle.
 Remove front wheels.
 Remove left front and right wheel housing liners --> 68 - INTERIOR EQUIPMENT .
Fig. 119: Hooking In Tensioner Hooks VW552 On Both Vehicles Sides In Upper Opening Of Wheel
Housing And In Upper Control Arm
 If equipped with air spring struts, the air line connection - 1 - must be loosened and allow air to escape.
Then, tighten connection to specified torque --> 40 - FRONT SUSPENSION .
 Hook tensioner hooks VW 552 onto each side of vehicle in upper openings of wheel housing - arrow A -
and in upper control arms - arrow B -.
 Pretension control arm slightly so that ball joint pin of control arm will not be damaged.
 Remove sound insulation below engine/transmission.
 If an underbody impact guard is located beneath the front final drive, remove it --> 50 - BODY -
FRONT .
 Remove sound insulation retainer.
Microsoft
Fig. 120: Removing/Installing Shield From Front Final Drive

 Remove shield from front final drive - arrows -.
Fig. 121: Removing Lower Three Bolts From Front Driveshaft At Front Final Drive
 Disconnect driveshaft from front final drive - arrows A - and tie up --> Front driveshaft, removing and
installing.
 Unbolt left and right drive axles. To loosen bolts, use socket insert T10099/1 if necessary.
Microsoft
Fig. 122: Identifying Universal Joint Bolt And Heat Shield

 If equipped, remove shield - A - from steering gear (2 bolts).

 Remove bolt - B - for universal joint on steering gear and pull universal joint from steering gear.
Fig. 123: Identifying Coolant Pipes, Nut & Bracket

 If equipped, remove coolant pipes - 1 - from left longitudinal member. When doing this, remove nut - A -
and bracket - arrow B -.
Fig. 124: Hooking Spindles 10 - 222 A/11 In Eyelets Of Engine Carrier On Left/Right Vehicle Sides
 Hook spindles 10 - 222 A/11 in eyes - arrow - of subframe on left and right sides of vehicle.
Microsoft
Fig. 125: Setting Wooden Block Into Hanger Of Each Spindle 10 - 222 A/11
 Set a wooden block - A - approx. 300 mm long into the hanger of each spindle 10 - 222 A/11.
 Hangers must face toward the rear.
 Tighten winged nuts of spindles , ensuring that wooden blocks lie against subframe - B -.
 Place insert from a trolley jack into engine/transmission jack V.A.G 1383 A.
Fig. 126: Placing Engine/Transmission Jack V.A.G 1383 A Under Engine Carrier
 Place engine/transmission jack V.A.G 1383 A under subframe and lightly press against it.
A - Wooden support
 Remove one of the subframe mounting bolts - arrows -.
Microsoft
Fig. 127: Checking Inner Contour Of Sleeve In Bonded Rubber Bushing

 Check inner contour of sleeve - arrow - in bonded rubber bushing.
Inner contour of sleeve

Rectangular Subframe cannot be secured.
 Mark position of subframe on body using a

felt tip pen.
Round Secure subframe before removal --> 40 - FRONT
SUSPENSION
 Remove mounting bolts for subframe from body - arrows - in Fig. 128.
Fig. 128: Removing/Installing Coupling Rods On Left/Right From Stabilizer Bar

 Disconnect left and right - 1 - coupling rods from stabilizer bar.

 Remove threaded connection from air spring strut or suspension strut to lower control arm. The subframe
must be lowered via the spindles 10 - 222 A/11 by approx. 50 mm direction of - arrow - to remove bolt -
2 -.
Microsoft
 Use bolts - 2 - with additional washers, or bolts M14 x 1.5 approx. 90 mm long, to secure subframe to
body on left and right - 3 -.
 Remove engine/transmission jack V.A.G 1383 A from under subframe.
Fig. 129: Placing Engine/Transmission Jack V.A.G 1383 A With Universal Transmission Adapter 1359/2
Under Subframe And Lightly Press Against It
 Place engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2 under subframe
and lightly press against it. When doing this, place wooden block - A - underneath subframe and - B -
under front final drive.
 Secure subframe with belt from universal transmission adapter V.A.G 1359/2.
 Remove spindles 10 - 222 A/11 from subframe.
Fig. 130: Pulling/Pushing Breather Line With Connecting Nipple Carefully Off Of Front Final Drive
 Pull breather line - A - with connecting nipple - arrow - carefully off of front final drive.
Microsoft
Fig. 131: Measuring Dimension Between Body And Fastening Surface Of Subframe
 Carefully lower subframe with front final drive to dimension - a - , approx 200 mm.
 Measure dimension - a - between body and fastening surface of subframe.
Fig. 132: Removing/Installing Bolts With Nuts For Front Final Drive On Subframe
 Remove bolts with nuts - 1 - through - 3 - for front final drive - A - on subframe - B -.
A second technician is required to remove front final drive.
Microsoft
Fig. 133: Removing Front Final Drive Rearward Between Subframe And Engine/Transmission
 Remove front final drive - 1 - rearward between subframe and engine/transmission as follows:
 Tie up left drive axle.
 Have second technician remove front final drive from supports in subframe.
 Guide right drive axle out of flange shaft.
 Raise front final drive over steering gear and guide out toward rear.
Front final drive, installing
Always replace bolts for front driveshaft.
A second technician is required to insert front final drive into subframe supports.
Microsoft
Fig. 134: Removing/Installing Bolts With Nuts For Front Final Drive On Subframe
 Install bolts with nuts - 1 - through - 3 - for front final drive - A - on subframe - B - --> 40 - FRONT
SUSPENSION .
 Raise subframe using transmission jack.
Fig. 135: Pulling/Pushing Breather Line With Connecting Nipple Carefully Off Of Front Final Drive
 Push breather line - A - with connecting nipple - arrow - carefully into front final drive. When doing so,
connecting nipple must be stand vertical and be inserted between raised areas of the housing.
Microsoft
Fig. 136: Hooking Spindles 10 - 222 A/11 In Eyelets Of Engine Carrier On Left/Right Vehicle Sides
 Hook spindles 10 - 222 A/11 in eyes - arrow - of subframe on left and right sides of vehicle.
Fig. 137: Setting Wooden Block Into Hanger Of Each Spindle 10 - 222 A/11
 Set a wooden block approx. 300 mm long into hanger of each spindle 10 - 222 A/11.
 Hangers must face rearward.
 Tighten winged nuts of spindles , ensuring that the wooden blocks lie against subframe - B -.
 Remove engine/transmission jack V.A.G 1383 A from under subframe.
 Place insert from a trolley jack into engine/transmission jack V.A.G 1383 A.
Microsoft
 Place engine/transmission jack V.A.G 1383 A under subframe and lightly press against it.
A - Wooden support
Fig. 139: Removing/Installing Coupling Rods On Left/Right From Stabilizer Bar

 Remove temporarily installed bolts - 3 - for subframe on left and right.

 Install bolts - 2 - for air spring strut or suspension strut on lower control arm.
 Fasten coupling rods on left and right - 1 - to stabilizer --> 40 - FRONT SUSPENSION .
Microsoft
Fig. 140: Checking Inner Contour Of Sleeve In Bonded Rubber Bushing

 Before bolting on subframe, check inner contour of bonded rubber bushing sleeve in subframe - arrow -.
Inner contour of sleeve

Rectangular  Vehicle must be aligned after assembling the
subframe --> 44 - WHEELS, TIRES,
WHEEL ALIGNMENT
Round  If steering wheel is crooked, a vehicle
alignment must be performed --> 44 -
WHEELS, TIRES, WHEEL
ALIGNMENT .
 Bolt on subframe - arrows - --> 40 - FRONT SUSPENSION
 If an axle alignment was performed, the bolts must be replaced --> 40 - FRONT SUSPENSION
 Tighten bolts to tightening torque --> 48 - STEERING .
 Remove spindles 10 - 222 A/11 from subframe.
Microsoft
Fig. 142: Identifying Universal Joint Bolt And Heat Shield

 Install universal joint on steering gear and tighten bolt - B - to tightening torque --> 40 - FRONT
SUSPENSION
 If equipped, install shield - A - to steering gear --> 40 - FRONT SUSPENSION .
Fig. 143: Identifying Coolant Pipes, Nut & Bracket

 If equipped, install coolant pipes - 1 - on left longitudinal member. When doing this, fasten nut - arrow A
- and bracket - arrow B - --> 82 AUXILIARY HEATER .
 Connect front driveshaft --> Front driveshaft, removing and installing.
Microsoft
Fig. 144: Removing/Installing Shield From Front Final Drive

 Install shield - arrows - and tighten bolts to 10 Nm.

 Install drive axles to flange shafts --> 40 - FRONT SUSPENSION .
 Remove tensioner hooks VW 552.
 Install left front and right wheel housing liners --> 66 - EXTERIOR EQUIPMENT .
 Check gear oil in front final drive --> Gear oil in front final drive, checking.
 If an underbody impact guard is located beneath the front final drive, install it --> 50 - BODY - FRONT .
 Install front wheels --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT .
 After installation, a vehicle alignment must be performed --> 44 - WHEELS, TIRES, WHEEL
ALIGNMENT .
Breather line for front final drive, routing
Fig. 145: Breather Line For Front Final Drive, Routing

The breather line - 1 - runs from front final drive - 3 - , along behind right engine mount - 4 - and then is clipped
to the air filter - 2 -.
Microsoft
SEALS AT FRONT FINAL DRIVE, REPLACING
Left flange shaft oil seal, replacing
Fig. 146: Identifying Special Tools - Left Flange Shaft Oil Seal, Replacing
 Punch VW 412
 Support channels VW 457
 Seal installer 2003/3
Microsoft
 Alignment fixture 3301

Fig. 147: Identifying Kukko Tools

Fig. 148: Thrust Plate T10260

Removing
 Remove front final drive --> Front final drive, removing.
Microsoft
Fig. 149: Securing Slide Hammer VW 771 To Left Flange Shaft

 Secure slide hammer VW 771 to left flange shaft.

 Pull out left flange shaft.
Fig. 150: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And
Additional Part For VW 771 771/37
 Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for
VW 771 771/37.
Installing
Microsoft
Fig. 151: Driving In New Oil Seal Up To Stop

 Drive in new oil seal up to stop.

Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary.
Fig. 152: Removing Old Circlip From Groove In Flange Shaft Using Pliers
 Remove old circlip - A - from groove in flange shaft using pliers.
B - Vise jaw protectors
 Insert new circlip in groove of flange shaft, being careful not to over-stretch circlip.
 Drive in flange shaft using a plastic head hammer.
 Install front final drive --> Front final drive, installing.
Dust cap for flange shaft, replacing
Microsoft
Fig. 153: Pressing Off Dust Cap From Flange Shaft

 Press off dust cap - B - from flange shaft.
Fig. 154: Pressing Dust Cap Onto Flange Shaft

 Press dust cap - A - onto flange shaft.
Set sleeve 3301/3 in place with recess - arrow - facing dust cap - A -.
Right flange shaft seal, replacing
Microsoft
Fig. 155: Slide Hammer-Multi-Purpose Tool Set VW 771




Removing
Microsoft
Fig. 157: Securing Slide Hammer VW 771 To Right Flange Shaft

 Secure slide hammer VW 771 to right flange shaft.

 Pull out right drive flange.
Additional Part For VW 771 771/37
VW 771 771/37.
Installing
Microsoft


Seal for driveshaft flange on front final drive, replacing (final drive removed)
Microsoft
Fig. 161: Identifying Special Tools - Seal For Driveshaft Flange On Front Final Drive, Replacing (Final
Drive Removed) (1 Of 2)

 Punch VW 407
 Punch VW 412
 Pulling hook 771/37

 Sleeve 40 - 20
Microsoft
Fig. 162: Identifying Special Tools - Seal For Driveshaft Flange On Front Final Drive, Replacing (Final
Drive Removed) (2 Of 2)
 Counter holder 3435

 Friction meter VAS 6222

 Loctite 648
 2 Bolts M10 x 25
Microsoft
Removing

 Lay front final drive on a workbench.
Fig. 163: Measure Friction Torque Using Friction Meter VAS 6222
 Before loosening drive pinion nut, measure friction torque.

 Note friction torque value. After seal is replaced, friction torque must be restored to this value.
 Use friction meter VAS 6222.
Fig. 164: Removing Hex Nut For Drive Shaft Flange

 Remove hex nut for drive shaft flange.
A - 2 Bolts M10 x 25
When loosening the nut of the driveshaft flange, counterhold using counter holder 3435 (2nd technician
required).
Microsoft
Fig. 165: Marking Installation Position Of Driveshaft Flange Relative To Drive Pinion
 Mark installation position of driveshaft flange - arrow A - relative to drive pinion - arrow B -.
 Pull off driveshaft flange. If difficult to remove, use slide hammer VW 771.
Fig. 166: Pulling Out Sealing Ring

 Pull out sealing ring.

 Clean threads for nut on drive pinion.
Installing
Microsoft


Before installing driveshaft flange, check dust cap for damage. Replace dust cap if necessary.
 Install driveshaft flange, being aware of marking from removal .

Fig. 168: Removing Hex Nut For Drive Shaft Flange

 Tighten new nut for drive pinion until friction torque measured prior to removal is attained .
A - 2 Bolts M10 x 25
When tightening the nut of the driveshaft flange, counterhold using counter holder 3435 (2nd technician
required)
Microsoft
Fig. 169: Measure Friction Torque Using Friction Meter VAS 6222
Increase tightening torque gradually, frequently measuring friction torque. The friction torque measured
prior to removal must not be exceeded! Otherwise front final drive must be replaced!

Dust cap for driveshaft flange, replacing
Fig. 170: Pressing Dust Cap Off Of Driveshaft Flange

 Press dust cap off of driveshaft flange.
Microsoft
Fig. 171: Pressing Dust Cap Onto Driveshaft Flange

 Press dust cap - A - onto driveshaft flange.
Installation position of dust cap: Depression on dust cap faces up toward sleeve 40 - 20.
NEEDLE BEARING FOR LEFT FLANGE SHAFT, REPLACING
Needle bearing for left flange shaft, replacing
Microsoft
Fig. 172: Identifying Special Tools - Needle Bearing For Left Flange Shaft, Replacing
 Mandrel 30 - 505
 Thrust pad 30 - 506 B
 - 1 - - Kukko 21/6 Internal puller
 - 4 - - Kukko 22/2 Counter-support
Needle bearing, removing

 Remove left flange shaft and seal --> Left flange shaft oil seal, replacing.
Microsoft
Fig. 173: Pulling Out Needle Bearing For Left Flange Shaft
 Pull out needle bearing for left flange shaft.
A - Internal puller 37 to 46 mm, e.g. Kukko 21/6
B - Counter support, e.g. Kukko 22/2
Needle bearing, installing
Fig. 174: Driving In Needle Bearing For Left Flange Shaft Up To Stop
 Drive in needle bearing - A - for left flange shaft up to stop.

 Install left flange shaft and seal --> Left flange shaft oil seal, replacing.
BONDED RUBBER BUSHING AT FRONT FINAL DRIVE, REPLACING
Bonded rubber bushing at front final drive, replacing
Microsoft
Fig. 175: Identifying Special Tools - Bonded Rubber Bushing At Front Final Drive, Replacing (1 Of 2)

 Sleeve 30 - 14
Microsoft
Fig. 176: Identifying Special Tools - Bonded Rubber Bushing At Front Final Drive, Replacing (2 Of 2)
 Thrust pad VW 512

 Alignment fixture T10030
Bonded rubber bushing, installation position
Bonded rubber bushings with 2 recesses
Microsoft
Fig. 177: Bonded Rubber Bushings With 2 Recesses

 The recesses in the bushing must be vertical relative to final drive - arrows -.

The smaller recesses - arrows - and smaller holes - A - of bushings must be vertical relative to final drive.
Bonded rubber bushing at driveshaft flange, pulling out and in
Microsoft
Fig. 179: Pulling Out Bonded Rubber Bushing

 Pull out bonded rubber bushing.
It is important to grease spindle 3346/2 with Molybdenum grease before using.
 Pull in bonded rubber bushing - A -.
Fig. 180: Pulling In Bonded Rubber Bushing

Pull in bonded rubber bushing - A - only so far until dimension - a - is achieved.
Microsoft
Fig. 181: Installation Depth For Bonded Rubber Bushing At Driveshaft Flange
 Installation depth for bonded rubber bushing at driveshaft flange.

 Dimension - a - = 47.5 mm
Bonded rubber bushing at front housing, pulling out and in

 To pull out, place special tool 3346/1 with flat shoulder facing toward bonded rubber bushing onto
spindle 3346/2.
Microsoft
Fig. 183: Pulling In Bonded Rubber Bushing Until It Is Centered In Front Final Drive Housing
 Pull in bonded rubber bushing - A - until it is centered in front final drive housing.
Bonded rubber bushing at extension tube for left flange shaft, pulling out and in
Removing and installing bonded rubber bushing on extension tube for left flange shaft is identical to the
procedure for removing and installing bonded rubber bushing on rear final drive --> Bonded rubber bushing
on rear final drive, replacing.
39R FINAL DRIVE, REAR DIFFERENTIAL

ELECTRICAL/ELECTRONIC COMPONENTS AND LOCATIONS FOR REAR FINAL DRIVE
DIFFERENTIAL LOCK
Electrical/electronic components and locations for rear final drive differential lock
Microsoft
Fig. 184: Electrical/Electronic Components And Locations For Rear Final Drive Differential Lock
1 - Differential lock control module J647
 Location --> Location of Differential lock control module J647

 Removing and installing --> Differential lock control module J647 , removing and installing
2 - Transfer case operating unit E473
 Location --> Location of transfer case operating unit E473

 Removing and installing --> 68 - INTERIOR EQUIPMENT .
3 - Differential lock motor V304
 Location --> Location of Differential lock motor V304

Microsoft
 Removing and installing --> Differential lock motor V304 , removing and installing
 The following components are integrated into differential lock motor V304 :
 Motor temperature sensor G407

 Differential lock position sensor 1 G460
 Differential lock position sensor 2 G461
 Brake for locking motor
4 - Data Link Connector (DLC)
 Location --> Data Link Connector (DLC)
5 - Multi-function display in instrument cluster
 Indicates condition and information about differential lock in rear final drive
Location of Differential lock control module J647
Fig. 185: Location Of Differential Lock Control Module J647

The differential lock control module J647 is located behind the side trim on the left rear wheel housing - arrow
-.
Differential lock control module J647 , removing and installing --> Differential lock control module J647 ,
removing and installing.
Location of transfer case operating unit E473
Microsoft
Fig. 186: Location Of Transfer Case Operating Unit E473

The transfer case operating unit E473 - 1 - is located in the shift cover - 2 - of the center console.
Transfer case operating unit E473 , removing and installing --> 70 - INTERIOR TRIM .
Location of Differential lock motor V304
Fig. 187: Setting Differential Lock Motor V304 With Holder For Connector Into Rear Final Drive
The differential lock motor V304 - A - is located in front of the left flange shaft on the rear final drive.
Differential lock motor V304 , removing and installing --> Differential lock motor V304 , removing and
installing
Data Link Connector (DLC)
Microsoft
Fig. 188: Data Link Connector (DLC)

The Data Link Connector (DLC) is located in the cover of the drivers side footwell.
Differential lock control module J647 , removing and installing
Removing
 Check whether a coded radio is installed. If so, obtain radio anti-theft coding.
 Switch ignition and all electrical consumers off, and remove ignition key.
 Disconnect Ground (GND) terminal connector from battery --> 27 - BATTERY, STARTER,
GENERATOR, CRUISE CONTROL .
 Remove left rear side trim --> 72 - SEAT - FRAMES .
Vehicles with Four-zone Climatronic
 Move rear auxiliary heater and air conditioner unit into service position --> 87 AIR CONDITIONING .
Continued for all vehicles
Fig. 189: Identifying Differential Lock Control Module J647 Connector, Bolt & Differential Lock Control
Module J647
Microsoft
 Separate connector - 1 - at differential lock control module J647.

 Remove bolt - 2 -.
 Unclip holder with differential lock control module J647 - 3 - from structure - arrows - and remove
holder with differential lock control module J647.
Installing
Fig. 190: Identifying Differential Lock Control Module J647 Connector, Bolt & Differential Lock Control
Module J647
 Clip holder with differential lock control module J647 - 3 - into structure - arrows -.
 Tighten bolt - 2 - to 2 Nm.
 Connect Ground (GND) terminal connector to battery and perform work sequences after connecting
battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
GEAR OIL IN REAR FINAL DRIVE, CHECKING
Gear oil in rear final drive, checking
Microsoft


The oil level is correct when the rear final drive is filled to the lower edge of the filler hole.
When initially filling rear final drive
 Remove bolt - arrow -.

Tightening torque
Oil filler plug to rear final drive 35 Nm
Microsoft
REAR FINAL DRIVE, REMOVING AND INSTALLING
Rear final drive, removing and installing
Fig. 193: Identifying Special Tools - Rear Final Drive, Removing And Installing

Rear final drive, removing
 Raise vehicle.
Microsoft
 If an underbody impact guard is located beneath the rear final drive, remove it --> 50 - BODY -
FRONT .
.
 Check whether there is a marking (colored marking) on rear driveshaft and on driveshaft flange at rear
final drive.
 If no markings can be found, mark in color the position of the driveshaft flange - arrow A - to rear final
drive - arrow B -.
Microsoft
Fig. 195: Disconnecting Rear Driveshaft From Rear Final Drive And Tie Up
 Disconnect rear driveshaft from rear final drive and tie up - arrow - --> Rear driveshaft, removing and
installing.
 If equipped, remove differential lock motor V304 --> Differential lock motor V304 , removing.
Fig. 196: Disconnecting Left/Right Drive Shafts And Tie-Up

 Disconnect left - 2 - and right - 1 - drive shafts and tie-up.

 Place engine/transmission jack V.A.G 1383 A with universal transmission adapter V.A.G 1359/2 under
rear final drive.
 Remove bolts and nuts for rear final drive at subframe - arrows -.
Microsoft
Fig. 197: Tipping Up Rear Final Drive At Driveshaft Flange

 Tip up rear final drive at driveshaft flange - A -.

 Lower rear final drive slightly and pull breather line off connection nipple.
 Lower rear final drive.
Rear final drive, installing
Always replace bolts for rear driveshaft.
 To prevent imbalance, the rear driveshaft flange - arrow A - and rear final drive - arrow B - must be
installed so that the colored markings from the factory or those subsequently made are in alignment.
Microsoft
Fig. 199: Fastening Rear Final Drive To Subframe

 Fasten rear final drive to subframe - arrows - --> 42 - REAR SUSPENSION .

 Fasten right - 1 - and left - 2 - driveshafts at flange shafts --> 42 - REAR SUSPENSION .
 If equipped, install the differential lock motor V304 --> Differential lock motor V304 , installing.
 Connect rear driveshaft --> Rear driveshaft, removing and installing.
 Install center bearing for driveshaft, so that it is free of stress --> Rear driveshaft center bearing,
installing stress-free.
 Check gear oil in rear final drive --> Gear oil in rear final drive, checking.
 If an underbody impact guard is located beneath the rear final drive, install it --> 50 - BODY - FRONT .
.
Breather line for rear final drive, routing
Microsoft
Fig. 200: Breather Line For Rear Final Drive, Routing

The breather line - A - runs from the rear final drive - B - over the subframe to connection - C -.
The breather line - A - is clipped into this.
DIFFERENTIAL LOCK MOTOR V304 , REMOVING AND INSTALLING
Differential lock motor V304 , removing and installing

Differential lock motor V304 , removing
 Separate two connectors at differential lock motor.
Microsoft
 Remove four bolts and remove differential lock motor differential lock motor - A - with holder for
connector - B -.
Differential lock motor V304 , installing
Fig. 203: Replacing O-Ring On Differential Lock Motor V304

 Replace O-ring - arrow - on Differential lock motor V304
NOTE:  Differential lock motor V304 is delivered as a replacement part with O-ring
Microsoft
installed.
 O-ring is secured with a protective sleeve.
 Remove protective sleeve before installing Differential lock motor V304.
 Set Differential lock motor V304 - A - with holder for connector - B - into rear final drive, and install and
tighten four bolts.
 Connect two connectors at Differential lock motor V304.
 Checking gear oil in rear final drive --> Gear oil in rear final drive, checking.
Tightening torque
Differential lock motor V304 at rear final drive 8 Nm
SEALS AT REAR FINAL DRIVE, REPLACING
Seal for left flange shaft, replacing (vehicles without differential lock)
Microsoft
Fig. 205: Identifying Special Tools - Seal For Left Flange Shaft, Replacing (Vehicles Without Differential
Lock)

 Punch VW 412
 Tube 3146
Microsoft

Removing
 Remove rear final drive --> Rear final drive, removing.


Microsoft
Fig. 208: Pulling Out Seal For Flange Shaft Using VW 771/1 And VW 771/37
 Pull out seal for flange shaft using VW 771/1 and VW 771/37.
Installing


Before installing the flange shaft, check the dust cap for damage. Replace dust cap if necessary.
Microsoft
 Install rear final drive --> Rear final drive, installing.

Microsoft

Seal for left flange shaft, replacing (vehicles with differential lock)
Microsoft
Fig. 213: Identifying Special Tools - Seal For Left Flange Shaft, Replacing (Vehicles With Differential
Lock)

 Punch VW 407
 Punch VW 412

 Sleeve 3144
Microsoft
Fig. 214: Identifying Kukko Tools


Removing
Microsoft


Fig. 217: Pulling Out Seal For Flange Shaft Using VW 771/1 And VW 771/37
VW 771 VW 771/37.
Installing
Microsoft


Microsoft


Seal for right flange shaft, replacing (vehicles without differential lock)
Microsoft




Removing
Microsoft


Additional Part For VW 771 VW 771/37
VW 771 VW 771/37.
Installing
Microsoft


Seal for right flange shaft, replacing (vehicles with differential lock)

Microsoft




Removing
Microsoft


Additional Part For VW 771 VW 771/37
VW 771 VW 771/37.
Installing
Microsoft


Sealing ring for driveshaft flange on rear final drive, replacing (final drive removed)
Microsoft
Fig. 234: Identifying Special Tools - Sealing Ring For Driveshaft Flange On Rear Final Drive, Replacing
(Final Drive Removed) (1 Of 2)

 Punch VW 407
 Punch VW 412

 Sleeve 40 - 20
Microsoft
Fig. 235: Identifying Special Tools - Sealing Ring For Driveshaft Flange On Rear Final Drive, Replacing
(Final Drive Removed) (2 Of 2)
 Handle-Hold Dr. Shaft Flange 3145 (change: expand holes to 10 mm diameter)

 Friction meter VAS 6222

 Loctite 648
 2 Bolts M10 x 25
Microsoft
Removing
 If necessary, expand holes in Counterhold 3145 to 10 mm diameter.

 Set rear final drive on a workbench.
Fig. 236: Measuring Friction Torque

 Before loosening drive pinion nut, measure friction torque.

 Note friction torque value. After seal is replaced, friction torque must be restored to this value.
 Use friction meter VAS 6222.
Fig. 237: Removing/Installing Flange/Drive Shaft Hex Nut

 Remove flange/drive shaft hex nut as follows:

 Secure Handle-Hold Dr. Shaft Flange 3145 with 2 bolts M10 x 25 to driveshaft flange - arrows -.
When loosening the driveshaft flange nut, counterhold using Handle-Hold Dr. Shaft Flange 3145 (2nd
technician required).
Microsoft
Fig. 238: Marking Installation Position Of Driveshaft Flange Relative To Drive Pinion
 Mark installation position of driveshaft flange - arrow A - relative to drive pinion - arrow B -.
 Pull off flange for driveshaft. If the task is difficult, use slide hammer VW 771.
771/37.
 Clean threads for nut on drive pinion.
Installing

 Drive new seal in as far as the stop; be sure not to distort seal.
Before installing driveshaft flange, check dust cap for damage. Replace dust cap if necessary.
 Install driveshaft flange, being aware of marking from removal .

Microsoft
Fig. 240: Removing/Installing Flange/Drive Shaft Hex Nut

 Tighten new nut for drive pinion until friction torque measured prior to removal is attained.
When tightening the nut of the driveshaft flange, counterhold using Handle-Hold Dr. Shaft Flange 3145
(2nd technician required).
Fig. 241: Measuring Friction Torque

Increase tightening torque gradually, frequently measuring friction torque. The friction torque measured
prior to removal must not be exceeded! Otherwise the rear final drive must be replaced!

Dust cap for driveshaft flange, replacing
Microsoft
Fig. 242: Pressing Dust Cap Off Of Driveshaft Flange

 Press dust cap off of driveshaft flange.
Fig. 243: Pressing Dust Cap Onto Driveshaft Flange

 Press dust cap - A - onto driveshaft flange.
Installation position of dust cap: Depression on dust cap faces up toward sleeve 40 - 20.
BONDED RUBBER BUSHING ON REAR FINAL DRIVE, REPLACING
Bonded rubber bushing on rear final drive, replacing
Microsoft
Fig. 244: Identifying Special Tools - Bonded Rubber Bushing On Rear Final Drive, Replacing

 Sleeve 30 - 14

Bonded rubber bushing, installation position
Microsoft
Fig. 245: Bonded Rubber Bushing, Installation Position

 The recesses in the bushing must be vertical relative to final drive - arrows -.

The smaller recesses - arrows - and smaller holes - A - of bushings must be vertical relative to final drive.
Bonded rubber bushing at driveshaft flange, pulling out and in
Always grease spindle 3346/2 with Molybdenum grease before inserting
Microsoft

 Pull in bonded rubber bushing - A - to stop.
Fig. 248: Pulling In Bonded Rubber Bushing To Stop

Rear bonded rubber bushing, pulling out and in
The process for pulling out and in the rear bonded rubber bushing at the rear final drive is identical to the
process for the bonded rubber bushing at the driveshaft flange --> Bonded rubber bushing at driveshaft
flange, pulling out and in.
Before pulling out a bonded rubber bushing, the corresponding flange shaft must first be removed --> Seal for
left flange shaft, replacing (vehicles without differential lock).
Microsoft

VW Touareg Front Rear-Differential

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

VW Touareg Front Rear-Differential

Uploaded by

Copyright:

Available Formats

2006 Volkswagen Touareg

REAR DIFFERENTIAL Rear Final Drive

Rear Final Drive

00 GENERAL, TECHNICAL DATA

Fig. 1: Drivetrain Guide, Overview

3 - Rear final drive

4 - Front final drive

TRANSFER CASE IDENTIFICATION

Transfer case identification

The transfer case 0AD is allocated to the automatic transmission 09D.

Off-road reduction gearing is integrated into the transfer case.

Location on transfer case

Location on transfer case - arrow -

Fig. 2: Location On Transfer Case

Code letters - arrow 1 - and date of manufacture - arrow 2 - of transfer case

Fig. 3: Code Letters And Date Of Manufacture Of Transfer Case

Additional data depends on manufacture.

Code letters, transmission allocation, gear ratios, capacities

Transfer case 0AD

Transfer case 0AD

Transfer case OAD

Application Model Touareg 2003 --> Touareg 2003 -->

Transfer case 0AD

Transfer case 0AD

Transfer case OAD

Transfer case OAD

Transfer case 0AD

Transfer case 0AD

Transfer case 0AD

FRONT FINAL DRIVE IDENTIFICATION

Front final drive identification

Front final drive identification, location

Location on front final drive - arrow -.

Fig. 4: Location On Front Final Drive

Code letters and date of manufacture of front final drive.

Additional data depends on manufacture.

Code letters, transmission allocation, gear ratios, capacities

Front final drive 0AA

Front final drive 0AA

Drive shaft flange dia. 114 mm 114 mm 114 mm

Front final drive 0AA

Front final drive 0AA

Front final drive 0AA

Front final drive OAA

Drive shaft flange dia. 114 mm 114 mm

REAR FINAL DRIVE IDENTIFICATION

Rear final drive identification

Location on rear final drive

Location on rear final drive - arrow -.

Fig. 6: Location On Rear Final Drive

Code letters and date of manufacture of rear final drive.

Fig. 7: Code Letters And Date Of Manufacture Of Rear Final Drive

Additional data depends on manufacture.

Code letters, transmission allocation, gear ratios, capacities

Rear final drive 0AB/0AC

Rear final drive 0AB/0AC

Application Model Touareg 2003 --> Touareg 2003 -->

Rear final drive 0AB/0AC

Rear final drive 0AB/0AC 0AB/0AC

Rear final drive 0AB/0AC

Rear final drive 0AB/0AC

Application Model Touareg 2004 -->

Rear final drive 0AB/0AC