Workshop Manual Transporter 2016 11-29

Service
Workshop Manual
Transporter 2016 ➤
Propshaft and rear final drive
Edition 01.2019
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
39 - Final drive - differential
satelettronica
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
Technical information should always be available to the foremen and mechanics, because their
a
do
riv
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
p
cum
for
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
en
ng
t.
yi Co
matter of course, be observed. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted
All rights reserved.
agen
Prote AG.
No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B805652B5

Propshaft and rear final drive - Edition 01.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety measures when using testers and measuring instruments during a road test . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Identification of final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Notes on performance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ge. n. A. G. ..V.ol.ks. w. a.g.en. A. G
. .d . . . . . . . . . . . . . . . . . . . 5
a oes
ksw n
4 Technical data . . . . . . . . . . . . . . . . . .b.y V. o.l . . . . . . . . . . . . . . . . . . . . . .ot.g.ua. . . . . . . . . . . . . 7
d r
4.1 Allocation final drive - engine . . . .or.is. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.nt.ee. . . . . . . . . .
e
7
th o
4.2 Capacities . . . . . . . . . . . . . . . s.au. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . . 8
s
satelettronica
ce
e
nl
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
pt
du
an
itte
y li
1 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
erm
ab
ility
1.1 Removing and installing final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ot p
wit
, is n
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
h re
hole
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
spec
2.2 Removing and installing bonded rubber bush on rear final drive . . . . . . . . . . . . . . . . . . . . 14
es, in part or in w
t to the co
2.3 Removing and installing bonded rubber bush on rear gearbox carrier . . . . . . . . . . . . . . . . 17
3 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
rrectness of i
3.1 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 High performance oil for all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
l purpos
4.1 Checking fluid level in all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2 Draining and replenishing high performance oil for all-wheel drive coupling . . . . . . . . . . . . 26
nf
ercia
orm
5 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
m
atio
m
5.1 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

o
n in
or c
5.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi 34

te
sd
a
5.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

iv
o
r
rp
cu
6 Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
o
m
f
en
ng
t.
6.1 Function of differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
yi Co
Cop py
6.2 Components of differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ht. rig
rig ht
py by
6.3 Removing and installing actuator for differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
co Vo
by lksw
cted
6.4 Renewing bellows on rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
agen
Prote AG.
7 All-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.1 Assembly overview - all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.3 Removing and installing pump for all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4 Removing and installing all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5 Removing and installing control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1 Assembly overview - propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.2 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3 Removing and installing centre propshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.4 Checking constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Contents i
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
satelettronica
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ii Contents
AG. Volkswagen AG d
agen oes
olksw not
00 – Technical data byV gu

ara
ed
ris nte
ho eo
aut ra
ss c
1 Safety information
ce
le
un
pt
an
d
itte
y li
(VRL012506; Edition 01.2019) erm
ab
ility
ot p
⇒ “1.1 Safety measures when working on vehicles with a start/
wit
stop system”, page 1
is n
h re
ole,
⇒ “1.2 Safety measures when using testers and measuring in‐
spec
struments during a road test”, page 1
t to the co
1.1 Safety measures when working on ve‐
hicles with a start/stop system
rrectnes
WARNING
s o
cial p
f in
Injury hazard as a result of automatic engine start in vehicles
form
mer
with start/stop system.
atio
om
♦ In vehicles with an activated start/stop system (indicated
n
c
satelettronica
i
or
n
by a message in the dash panel insert), the engine may
thi
te
sd
a
start automatically.
iv
o
pr
cum
r
fo
♦ When working on the vehicle, always make sure that the
en
ng
t.
start/stop system is deactivated (switch off the ignition;
yi Co
op
switch the ignition on again if necessary).
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.2 Safety measures when using testers
and measuring instruments during a
road test
To prevent personal injury and material damage to the vehicle,
observe the following:
WARNING
Vehicles with dual clutch gearbox - risk of injury and accident

by accidental engagement of gear while engine is running.
♦ Before working on vehicle with engine running, move se‐
lector lever into position “P” and apply parking brake.
Risk of poisoning!
♦ While the engine is running, an exhaust gas extraction
system must be attached to the exhaust system.
1. Safety information 1
Observe the following if test and measuring instruments are re‐

quired during a road test:
WARNING
Risk of accident due to distraction and inadequate securing of

test and measuring equipment
Danger as a result of activation of front passenger airbag in the
event of an accident
• Operation of test and measuring equipment while driving
results in distraction.
• Greater injury hazard as a result of unsecured test and
measuring equipment.
♦ Always strap in place test and measuring equipment on
rear seat and have a 2nd person sitting on the rear seat
to operate them.
To prevent personal injury and damage to or destruction of elec‐

trical and electronic components, observe the following:
satelettronica
♦ Connect and disconnect measuring and testing devices only
with the ignition switched off.
Caution
Risk of irreparable damage to electronic components when AG. Volkswagen AG d

disconnecting battery. olksw
agen oes
not
byV gu
♦ Observe the necessary measures when disconnecting theris d ara
e nte
battery. ut
ho eo
ra
s a c
♦ Disconnect battery only after the ignition has been switch‐
s
ce
e
nl
ed off.
pt
du
an
itte
y li
erm
ab
ility
ot p
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
wit
, is n
Disconnecting and connecting battery .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2 Rep. gr.00 - Technical data

2 Identification
⇒ “2.1 Identification of final drive”, page 3
2.1 Identification of final drive

Rear final drive -arrow 1-
Code letters and production date of rear final drive -arrow 2-
Example: FXD 03 12 03
I I I I
I I I I
Codes Day Month Year 2003 of man‐ Volkswagen AG
ufacture swagen AG. does
k not
Vol gu
by
Additional data depend on manufacture. ris
ed ara
nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
satelettronica
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Identification 3
3 Repair notes
⇒ “3.1 General repair instructions”, page 4
⇒ “3.2 Gaskets and seals”, page 5
⇒ “3.3 Nuts and bolts”, page 5
⇒ “3.4 Notes on performance test”, page 5
⇒ “3.5 Oil”, page 5
3.1 General repair instructions

⇒ “3.1.1 Oil”, page 4
⇒ “3.1.2 Bearings”, page 4
⇒ “3.1.3 Shims”, page 5
3.1.1 Oil
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.
satelettronica
♦ Allocate bolts and other components using ⇒ Electronic parts
catalogue (ETKA) .
♦ When exchanging rear final drive, check oil level in all-wheel
drive coupling and final drive and replenish if necessary.
♦ Check gear oil in rear final drive ⇒ page 23 .
AG. Volkswagen
♦ Check fluid level of all-wheel drive coupling
lksw
agen ⇒ page 25AG. does n
o ot g
yV ua
♦ Capacities and specifications
ris
ed b ⇒ page 7. ran
tee
ho
aut or
ac
ss
Note
ce
e
nl
pt
du
an
itte
y li
The final drive and all-wheel drive coupling have separate »oil
erm
ab
circuits«.
ility
ot p
wit
, is n
h re
The final drive is filled with “axle oil”, the all-wheel drive coupling
hole
spec
is filled with “high performance oil for all-wheel drive coupling”.

es, in part or in w
t to the co
Oil for the “final drive” and oil for the “all-wheel drive coupling” are
available as replacement parts ⇒ Electronic parts catalogue (ET‐
KA) .
rrectness of i
Do not mix »additives« in oil.

l purpos
Oil which has been drained out cannot be added again.

nf
ercia
Caution
rm
m
atio
om
Use caution when handling oil. Dispose of used oil properly.

n in
or c
One drop of oil will contaminate 1,000 litres of water.

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
3.1.2 Bearings
t.
yi Co
Cop py
t. rig
♦ Install new tapered roller bearings as supplied and do not lu‐ gh ht
yri by
bricate additionally.
op Vo
by c lksw
cted agen
Prote AG.
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.

♦ Heat inner races to about 100° C before installing.

♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
3.1.3 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
3.2 Gaskets and seals

♦ Thoroughly clean parting surfaces, and apply sealing paste ⇒
Electronic parts catalogue (ETKA) .
♦ Apply sealant uniformly but not too thick.
♦ Renew sealing rings.
Radial oil seal for propshaft flange on rear final drive
satelettronica
Before installing, lightly oil space on external circumference be‐
tween sealing lips with high performance oil for all-wheel drive
coupling (specification for high performance oil for all-wheel drive
coupling ⇒ Electronic parts catalogue (ETKA) ).
After installation, check oil level in all-wheel drive coupling and
replenish if necessary ⇒ page 25 .
AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
3.3 Nuts and bolts

y li
erm
ab
ility
ot p
♦ Loosen and tighten bolts and securing nuts for covers and
wit
is n
housings in diagonal sequence.

h re
ole,
spec
♦ Delicate parts in particular must not be canted. Loosen and

tighten in stages in a diagonal sequence.

t to the co
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Always renew self-locking bolts and nuts.
rrectne
♦ Ensure with threaded connections that contact surfaces as

well as nuts and bolts are rewaxed only after assembly, if nec‐
ss o
essary.
cial p
f inform
♦ Use a thread chaser to clear residual locking fluid from all

mer
threaded holes into which self-locking bolts are to be screwed.

atio
m
Otherwise there is a danger of bolts shearing when subse‐

o
n
c
i
or
quently being removed.

thi
te
sd
va
3.4 Notes on performance test

i
o
pr
cum
r
fo
en
ng
– Only rolling roads with brakes on all 4 rollers may be used for
t.
yi Co
op
performance tests. C py
t. rig
gh ht
yri by
3.5 Oil
cop Vo
by lksw
cted agen
Prote AG.
Note
The final drive and all-wheel drive coupling have separate »oil
circuits«.
3. Repair notes 5
The final drive is filled with “axle oil”, the all-wheel drive coupling
is filled with “high performance oil for all-wheel drive coupling”.
Oil for the “final drive” and oil for the “all-wheel drive coupling” are
available as replacement parts ⇒ Electronic parts catalogue “ET‐
KA” .
Do not mix »additives« in oil.
Oil which has been drained out cannot be added again.
Caution
Be careful when working with oil. Dispose of drained oil ac‐

cording to regulations. Remember: one drop of oil will contam‐
inate 1,000 litres of water.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
satelettronica
th eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Technical data
⇒ “4.1 Allocation final drive - engine”, page 7
⇒ “4.2 Capacities”, page 8
4.1 Allocation final drive - engine

⇒ “4.1.1 Allocation final drive - engine, dual clutch gearbox”, page
7
⇒ “4.1.2 Allocation final drive - engine, manual gearbox”,
page 7
4.1.1 Allocation final drive - engine, dual clutch gearbox

Rear final drive 0CD
Gearbox type 7-speed dual clutch gearbox 0BT
Codes PYQ PYR QUD
Engine 2.0 l - 132 kW 2.0 l - 132 kW 2.0 l - 110 kW
turbo diesel turbo diesel turbo diesel
2.0 l - 150 kW 2.0 l - 150 kW 2.0 l - 132 kW
satelettronica
FSI turbo diesel turbo diesel
2.0 l - 150 kW 2.0 l - 150 kW
FSI turbo diesel
Refer to ⇒ Electronic parts catalogue (ETKA) for following data:
♦ Production dates
♦ Final drive ratio
♦ Gear oil
♦ Allocation of drive
wage
shaft
n AG. Vflanges
olkswagen AG
doe
ks s no
Vol t gu
♦ The allocation
ed
by of the manual gearbox ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an

itte
y li
erm
ab
Gearbox type 7-speed dual clutch gearbox 0BT

ility
ot p
Codes QUE RMF RMG

wit
, is n
h re

hole
spec

es, in part or in w
2.0 l - 132 kW
t to the co
turbo diesel
2.0 l - 150 kW
turbo diesel
rrectness of i

l purpos
nform
ercia
♦ Gear oil
m
at
om
♦ Allocation of drive shaft flanges

on
c
in t
or
♦ The allocation of the manual gearbox

his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
4.1.2 Allocation final drive - engine, manual gearbox
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Gearbox type 6-speed manual gearbox 0A5

Codes PYQ PYR QUD
4. Technical data 7

2.0 l - 103 kW 2.0 l - 103 kW 2.0 l - 110 kW
2.0 l - 132 kW 2.0 l - 132 kW 2.0 l - 132 kW
nAG. Volkswagen2.0 l - 150 kW
AG do
olks
wage FSI
es n
o
yV t gu
Refer to ⇒ Electronic parts catalogue (ETKA) for following data: ed
b ara
nte
ris
♦ Production dates ut
ho eo
a ra
ss c
ce
le
un
pt
♦ Gear oil
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
Gearbox type 6-speed manual gearbox 0A5
rrectness of i
Codes QUE RMF RMG
l purpos

nform
ercia
2.0 l - 110 kW
turbo diesel
m
a
2.0 l - 132 kW
com
tion in
turbo diesel
r
te o
2.0 l - 150 kW
thi
s
iva
turbo diesel
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
♦ Final drive ratio opyri
gh by
Vo
ht
by c
♦ Gear oil
lksw
cted agen
Prote AG.
4.2 Capacities
(All-wheel drive coupling generation V)
Final drive capaci‐ approx. 1.1 litre
ty
Capacity of all- approx. 1.1 litre
wheel drive cou‐
pling
Replacement vol‐ approx. 0.95 l
ume in all-wheel
drive coupling
• Change inter‐
vals: ⇒ Mainte‐
nance tables

39 – Final drive - differential

1 Final drive
⇒ “1.1 Removing and installing final drive”, page 9
1.1 Removing and installing final drive

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-
wage es n
satelettronica
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
♦ Engine and gearbox jack - VAS 6931-
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Locating pins - T10486-

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Disconnect left and right drive shafts, swing forwards and tie
up. When doing this, do not damage surface protection.
– Disconnect propshaft at rear final drive ⇒ page 56 .
1. Final drive 9
Note
It is not necessary to remove the rear propshaft completely.
– Pull breather hoses -1- and -3- off rear final drive.
– Separate connector -2-.
– Place cloths or a foam underlay on engine and gearbox jack -
VAS 6931- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
– Place engine and gearbox jack beneath rear final drive and
itte
y li
erm
press against final drive lightly.
ab
ility
ot p
satelettronica
– Unscrew rear bolts -arrows- from gearbox carrier.
wit
is n
h re
ole,
spec
Note
t to the co
Hole diameters on the gearbox carrier may differ.
rrectne
Gearbox carrier with M12 bolts
s
– Screw locating pins - T10486/1- in rear threads -arrows-.
s o
cial p
f i
Gearbox carrier with M10 bolts
nform
mer
– Screw locating pins - T10486/2- in rear threads -arrows-.

atio
om
n
Continued for all vehicles
c
i
or
n thi
te
sd
va
– Remove handbrake cable -2- of handbrake from bracket -1-.

i
o
pr
cum
r
fo
en
ng
– Unscrew front securing bolt -3- from gearbox mount.

t.
yi Co
Cop py
– Lower rear final drive slightly and place propshaft on anti-roll
t. rig
gh ht
yri
bar. p by
o Vo
by c lksw
cted agen
Prote AG.
10 Rep. gr.39 - Final drive - differential

Vehicles with differential lock

– Detach vacuum lines -2- and -3- from vacuum unit -1-.
– Connector -4- is not detached.
– Lower final drive completely.
• The rear final drive must be raised slightly in the area of the
propshaft flange and guided over the anti-roll bar.
• On vehicles with differential lock, guide right drive shaft past
rear final drive.
Note
A second mechanic is required to lower.
Removing and installing bonded rubber bush on rear final drive

⇒ page 14 .
Removing and installing bonded rubber bush on gearbox carrier
satelettronica
⇒ page 17 .
Installing
Install in reverse order of removal, observing the following:
If cross member and gearbox carrier have been removed from
rear final drive:
– Always renew securing bolts from cross member and gearbox
carrier.
Cross member -2- only fits onto rear Vfinal

olksw
drive -3- in one position.
Oval hole -arrow- must besat en AG. right.agen AG doe
wagbottom s olk not
yV g
– Screw on crossisemember
db »hand-tight« using new bolts
ua
r-1-
an .
r tee
ho
– Then align athe
ut cross member centrally to the bolt holes. Tight‐
or
ac
ss ⇒ page 13 .
en bolts -1-
ce
le
un
pt

an
d
itte
y li
erm
ab
– Raise rear final drive with engine and gearbox jack - VAS
ility
ot p
6931- .
wit
is n
h re
• When installing final drive, also position propshaft on prop‐

ole,
shaft flange at same time.

spec
• The rear final drive must be raised slightly in the area of the
t to the co
propshaft flange and guided over the anti-roll bar.

rrectne
Note
ss
A second mechanic is required to install.

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Final drive 11

– Push vacuum lines -2- and -3- onto vacuum unit -1-.
♦ -2- - Vacuum line “green”
♦ -3- - Vacuum line “blue”

– Bolt gearbox carrier to body using new bolts »hand-tight«.
Note
Watch the locating pins - T10486- and align the gearbox carrier
to the body.
satelettronica
– Then tighten bolts -arrow 1- and -arrows 2- ⇒ page 13 .
AG. Volkswagen AG d
– Install propshaft -A- ⇒ page 56 . agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
– Push breather hoses -1- andaut-3-
h onto rear final drive.
ra
ss c
– Fit electrical connector -2-.
ce
e
nl
pt
du
an
– Install left and right drive shafts ⇒ Running gear, axles, steer‐
itte
y li
erm
ing; Rep. gr. 42 ; Drive shaft; Removing and installing drive

ab
ility
shaft .
ot p
wit
, is n
– Check fluid level of all-wheel drive coupling ⇒ page 25 .

h re
hole
spec
– Check gear oil in rear final drive ⇒ page 23 .

es, in part or in w
t to the co
Torque settings
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 13
rrectness of i
♦ ⇒ “8.1.2 Assembly overview - propshaft, long wheelbase”,

l purpos
page 52
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Drive shaft;
nform
ercia
Assembly overview - drive shaft

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 13
⇒ “2.2 Removing and installing bonded rubber bush on rear final
drive”, page 14
⇒ “2.3 Removing and installing bonded rubber bush on rear gear‐
box carrier”, page 17
2.1 Assembly overview - assembly mountings
1 - Rear final drive

❑ Removing and installing
⇒ page 9
2 - Cross member agen
AG. Volkswagen AG d
oes
lksw not
❑ Fits on rear final drive in by Vo gu
ara
one position only rise
d
nte
ho eo
❑ Removing and installing s aut ra
c
⇒ page 11 s
ce
le
satelettronica
un
pt
3 - Bolt
an
d
itte
y li
❑ Renew after removal
erm
ab
ility
ot p
❑ M
wit
is n
❑ 90 Nm +90°
h re
ole,
spec
4 - Shim
t to the co
5 - Bolt
rrectne
❑ M 10 x 110
❑ 50 Nm +180°
ss o
6 - Bolt
cial p
f in
form
mer
❑ 90 Nm +180°
atio
om
n
c
7 - Bevel box carrier
i
or
n thi
te
❑ Removing and installing sd

iva
o
r
⇒ page 9
p
cum
r
fo
en
ng
❑ Renewing bonded rub‐ yi

t.
Co
ber bush for subframe t. Cop py
⇒ page 14
rig
gh ht
pyri by
Vo
co
8 - Bolt
by lksw
cted agen
Prote AG.
❑ M 12 x 1.5 x 100
❑ 90 Nm +180°
9 - Shim
2. Assembly mountings 13
2.2 Removing and installing bonded rubber

bush on rear final drive
⇒ “2.2.1 Removing and installing front bonded rubber bush for
rear final drive”, page 14
⇒ “2.2.2 Removing and installing rear bonded rubber bush for rear
final drive”, page 15
2.2.1 Removing and installing front bonded

rubber bush for rear final drive
♦ Assembly tool - T50008-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
♦ Assembly tool - 3346-

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing
m
– Remove rear final drive together with gearbox carrier

a
com
tio
⇒ page 9 .
n in
r
te o
thi
– Remove gearbox carrier from rear final drive ⇒ page 13 .

s
iva
do
r
rp
– Mark installation location of bonded rubber bush for gearbox,

um
fo
en
e.g. using felt pen.

ng
t.
yi Co
op py
– Fit special tools as shown in figure.
. C rig
ht ht
rig by
py
1- Threaded rod - 3346/2-
co Vo
by lksw
cted agen
Prote AG.
2- Bracket - T50008/2-
3- Tube - T50008/1-
4- Press tool - T50008/3-
5- Nut - 3346/3-
– Take up play in special tools.
– Turn threaded rod -1- to pull out bonded rubber bush.

Installing
1- Threaded rod - 3346/2-
2- Nut - 3346/3-
3- Press tool - T50008/4-
4- Tube - T50008/1-
5- Bracket - T50008/2-
– Turn threaded rod -1- to pull in bonded rubber bush.
The flange of the bonded rubber bush must overlap the gearbox
support -arrows-.
– Install gearbox carrier on rear final drive ⇒ page 13 .
– Install rear final drive together with gearbox carrier ⇒ page 9 .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V
2.2.2 Removing and installing rear bonded
by gu
d ara
ise nte
r
rubber bush for rear final drive
ho eo
aut ra
ss c
ce

le
un
pt
an
d
itte
♦ Assembly tool - T50008-

y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
♦ Press tool - VW 411-

a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
Removing agen oes
olksw not
V gu
by ara
– Remove rear final drive together
rised
with gearbox carrier nte
⇒ page 9 . aut
ho eo
ra
ss c
ce
le
un
pt
an
d
– Unscrew bolts -1- and remove cross member -2-.

itte
y li
rm
ab
– Mark installation location of bonded rubber bush for gearbox,
pe
ility
e.g. using felt pen.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press bonded rubber bush out of cross member as shown in
rrectness of i
figure.
l purpos
nform
mercia
a
com
tion in
satelettronica
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Installing yri
p by
o Vo
by c lksw
cted
– Press bonded rubber bush into cross member as shown in
agen
Prote AG.
figure.
– Thrust piece - T50008/4- must be pressed completely to cross
member.
The flange of the bonded rubber bush must overlap the gearbox
support -arrows-.
– Install cross member.

Cross member -2- only fits onto rear final drive -3- in one position.
Oval hole -arrow- must be at bottom right.
– Screw on cross member »hand-tight« using bolts -1-.
– Then align the cross member centrally to the bolt holes. Tight‐
en bolts -1-.
Torque settings
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
2.3 Removing and installing bonded rubber
satelettronica
wit
, is n
bush on rear gearbox carrier
h re
hole
spec
⇒ “2.3.1 Removing and installing front bonded rubber bush for
es, in part or in w
t to the co
rear gearbox carrier”, page 17
⇒ “2.3.2 Removing and installing rear bonded rubber bush for rear
gearbox carrier”, page 20
rrectness of i
2.3.1 Removing and installing front bonded
l purpos
rubber bush for rear gearbox carrier
nf
ercia
o
rm
m
atio
m
♦ Thrust plate - VW401- and -VW402-

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Press tool - VW412-
♦ Tube - 30-14-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Removal wedge - 3409-
rrectness o
cial p
f inform
mer
satelettronica
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
♦ -1- Two-arm puller , e.g. -Kukko 20–10- (VAS 251 001) C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Tensioner - 40-204A-

♦ Thrust piece - 3236-
Removing
⇒ page 9 .
– Push thrust plate - VW 401- under edge -B- up to gearbox
carrier as far as it will go.
satelettronica
. Volkswagen AG
– Press out bonded rubber bush -C- with thrust piece - 3236- wage
n AG does
olks
and two-arm puller -A- in opposite direction of installation.
V
not
gu
by ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
Installing
itte
y li
erm
ab
– Before pressing in, coat rubber bead of bonded rubber bush
ility
ot p
with lubricant, e.g., soft soap.
wit
is n
h re
– Place bonded rubber bush with surfaces -arrows 1- in instal‐
ole,
spec
lation position. Lugs -arrow 2- point in direction of travel.
t to the co
Angle -α- is 5° ± 3°.
rrectness o
cial p
– Fit special tools as shown in figure. f inform

mer
atio
m
• Position tensioner - 40 - 204 A- on bonded rubber bush -A- in

o
n
c
such a way that lugs are not damaged.

or
n thi
te
sd
a
– Press bonded rubber bush in to stop.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– After pressing in, lever out rubber bead of bonded rubber bush
-A- using removal wedge - 3409- .
2.3.2 Removing and installing rear bonded rubber bush for rear gearbox carrier
Special tools and workshop

equipment required
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
♦ Crankshaft seal installing tool - VW 204 B-

i
or
n thi
te
sd
a
♦ Thrust plate - VW 401-

iv
o
pr
cum
r
fo
♦ Thrust plate - VW 402-

en
ng
t.
yi Co
op
♦ Press tool - VW 407- C py
t. rig
gh ht
yri by
♦ Press tool - VW 412- cop Vo
by lksw
cted agen
Prote AG.

♦ Sleeve - 3144- or tube - 30 - 14-

swage es n
♦ Splitter - VAS 6180/2- byV
olk ot g
ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Assembly tool - 3253-
l purpos
nform
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ Thrust piece - 2007- cted agen
Prote AG.
Removing
⇒ page 9 .

– Press out rear bonded rubber bush.
• The jaws of the separating device - VAS 6180/2- must make
contact between the collar of the bonded rubber bush and the
hole for the bush in the rear final drive carrier.
Installing
– Before pressing in, coat rubber bead of bonded rubber bush
with lubricant, e.g., soft soap.
– Press in bonded rubber bush -A- as far as it will go.
satelettronica
– After pressing in, lever out rubber bead of bonded rubber bush
-A- using removal wedge - 3409- .
– Install gearbox carrier on rear final wage
olks drive ⇒ page 13 .
es n
V ot g
by ua
– Install rear final drive together
ris
ed with gearbox carrier ⇒ page 9 . ran
tee
tho or
s au ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3 Gear oil
⇒ “3.1 Checking gear oil level”, page 23
3.1 Checking gear oil level

. Volkswagen AG
gen AG does
Vol
ksw
a
not
y gu
db ara
♦ Torque wrench - V.A.G 1410- rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
♦ Filling device for all-wheel drive coupling - VAS 6291 A-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ If necessary, use adapter - VAS 6262/6-
♦ Drip tray for workshop hoist - VAS 6208-
3. Gear oil 23
Requirement
• Vehicle is level.
• In order to perform the oil level check, the final drive must be
in installation position.
Allocate oil for rear final drive using ⇒ Electronic parts catalogue
(ETKA) .
Check fluid level
– Remove oil filler plug -1-.
The oil level is correct when the rearAfinal drive is filled to the lower
G. Volkswagen AG d
edge of the filler hole. lksw
agen oes
n o ot g
yV ua
– Screw in oil filler rplug
ise
d b and tighten to specified torque. ran
tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
satelettronica
Observe the following for initial filling:
hole
spec
– Place drip tray for workshop hoist - VAS 6208- under final
es, in part or in w
t to the co
drive.
– Using filling device for all-wheel drive coupling - VAS 6291 A- , rrectness of i
add enough oil so that it runs out between the adapter of the
l purpos
filling device and the gear housing.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
– Renew oil seal -arrow- of oil filler plug.

do
r
rp
cum
fo
– Screw in oil filler plug and tighten to specified torque.

en
ng
t.
yi Co
Torque settings Cop py
t. rig
gh ht
yri by
Component Specified torque
cop Vo
by lksw
cted agen
Prote
Hydraulic fluid filler plug 15 Nm
AG.

4 High performance oil for all-wheel

drive coupling
⇒ “4.1 Checking fluid level in all-wheel drive coupling”,
page 25
⇒ “4.2 Draining and replenishing high performance oil for all-
wheel drive coupling”, page 26
4.1 Checking fluid level in all-wheel drive

wage
coupling by
Volks es n
ot g
ua d ran
se
Special tools and workshop equipmentthrequired
or
i tee
or
au ac
♦ Torque wrench - V.A.G 1331- ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Vehicle diagnostic tester

♦ Acid-resistant protective gloves
Conditions for testing
• Observe safety data sheet.
• The oil temperature must be between 20 and 40 °C.
• In order to perform the oil level check, the final drive must be
in installation position.
– Read oil temperature ⇒ Vehicle diagnostic tester Guided
functions .
Starting “Guided functions”:

– Switch on ignition.
– Touch “Guided functions” section/button on screen.
– Select one after the other on the display of vehicle diagnostic
tester:
4. High performance oil for all-wheel drive coupling 25

♦ Brand
♦ Model
♦ Model year
♦ Version
♦ Engine code
♦ Confirm input data.
♦ 22 - All-wheel drive electronics
♦ 22 - Read measured value block
♦ Oil temperature
– Read oil temperature.
• Oil temperature must be 20 to 40°C.
Check fluid level
Oil level is correct when all-wheel drive coupling is filled to lower
edge or at least to within about 3 mm of lower edge of filler hole.
satelettronica
– If oil level is incorrect, oil must be replenished ⇒ page 28 .

– Tighten oil filler plug -1- to specified torque
⇒ Item 2 (page 44) . AG. Volkswagen AG d
agen oes
olksw not
V gu
Torque settings ed by ara
nte
ris
ho eo
♦ ⇒ “7.1 Assembly overview - all-wheel drive coupling”, aut ra
c
page 44 ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
4.2 Draining and replenishing high perform‐

es, in part or in w
t to the co
ance oil for all-wheel drive coupling

rrectness of i
Note
l purpos
♦ Only replenish the high performance oil for all-wheel drive

coupling .
nform
ercia
♦ Allocate high performance oil for all-wheel drive coupling using

m
at
om
⇒ Electronic parts catalogue (ETKA) .

ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in
satelettronica
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Torque wrench - V.A.G 1331-

Torque wrench - V.A.G 1410-
Used oil collection and extraction unit - V.A.G 1782- has been
discontinued; use used oil collection and extraction unit - VAS
6622A- instead
Drip tray for workshop hoist - VAS 6208-
Charging device for all-wheel drive coupling - VAS 6291 A- ; use
adapter - VAS 6262/6- if necessary
Vehicle diagnostic tester
Conditions for testing
• Observe safety data sheet.
• The oil temperature must be between 20 and 40 °C.
4. High performance oil for all-wheel drive coupling 27

Draining
Caution
Risk of injury
• Wear acid-resistant gloves
– Position used oil collection and extraction unit - VAS 6622A-

under final drive.
– Unscrew drain plug -arrow- and drain high performance oil for
G. Volkswagen AG d
all-wheel drive coupling completely.lkswagen A oes
n o ot g
yV ua
db ran
ir se tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
satelettronica
h re
hole
spec
es, in part or in w
t to the co
– Renew oil seal -arrow- of drain plug.
– Screw in drain plug and tighten to specified torque
rrectness of i
⇒ Item 3 (page 44) .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Filling Cop py
t. rig
gh ht
yri
– Place drip tray for workshop hoist - VAS 6208- under final p by
co Vo
drive.
by lksw
cted agen
Prote AG.

– Screw adapter - 6291/1- -A- in to stop.

– Engage elbow -B- in adapter -A-.
– Using filling device - VAS 6291 A- , add enough fluid so that it
runs out between the adapter of the filling device and the final
drive housing.
– Remove filling device and adapter; excess fluid may still run
out.
Fluid level is correct when all-wheel drive coupling is filled to lower
edge of filler hole.
satelettronica
– Screw in oil filler plug -1- and tighten to specified torque
⇒ Item 2 (page 44) .
Torque settings olkswage es n
ot g
V
by ua
♦ ⇒ “7.1riAssembly
se
d overview - all-wheel drive coupling”,
ran
tee
page
ut 44
ho
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
29
op Vo
by c lksw
Prote
cted AG.
agen 4. High performance oil for all-wheel drive coupling
5 Oil seals
⇒ “5.1 Renewing right oil seal”, page 30
⇒ “5.2 Renewing left seal”, page 34
⇒ “5.3 Renewing input shaft seal”, page 38
5.1 Renewing right oil seal

satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
♦ Puller - T10055-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o e
aut
h
Transporter 2016 ➤ or a
s c
s Propshaft and rear final drive - Edition 01.2019
ce
e
nl
pt
du
an
♦ Thrust piece - T10032-
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng t.
yi Co
Cop py
ht. rig
satelettronica
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Hexagon key - V.A.G 1669-
Removing
• Differential lock must be disengaged (not actuated).
– Unbolt drive shaft from rear final drive.
– Lower gearbox carrier with rear final drive ⇒ page 9 .
– Push drive shaft over rear final drive up to middle.
– Place drip tray for workshop hoist - VAS 6208- under rear final
drive.
5. Oil seals 31

– Screw 2 bolts into flange to allow for counterholding.
AG. Volkswagen
– Unscrew securing bolt lfor
ksw right flange shaft.
agen AG do
es n
o ot g
yV u
A - Hexagon key - rV.A.G
ised b 1669- or 6 mm bit (commerciallyaravail‐
an
t
able) ut
ho
ee
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Screw thread adapter, e.g. Kukko 18–0 -A-, into right flange
shaft -1-.
rrectne
– Pull out flange shaft using puller - T10055- and adapter -
T10055/3- .
s
– Carefully drill a 4 mm hole into oil seal.
s o
cial p
satelettronica
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
– Screw self-tapping screw -2- into seal -1-.

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Note opyri
gh by
Vo
ht
by c lksw
cted
Do not screw in sheet metal screw too far to avoid damaging
agen
Prote AG.
bearing behind it.
– Pull out seal -1- using puller - T10055- and adapter -

T10055/2- .
– Remove any swarf from final drive.

Installing
. Volkswagen AG
Install in reverse order of removal, observing the following: kswagen AG does
not
Vol gu
– Lightly oil outer circumference of oil seal and half-fill by
dspace ara
e nte
ris
between sealing lips -arrow- with grease . ut
ho eo
a ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Drive in seal to stop with thrust piece - T10032- , being careful
not to cant seal.
rrectness of i
l purpos
nf
ercia
or
satelettronica
m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Vehicles without differential lock

t.
yi Co
Cop py
t. rig
– Clamp flange shaft in vice with protective jaw covers. opyri
gh by
Vo
ht
by c
– Use new retaining ring -A- to press old retaining ring out of
lksw
cted agen
Prote
groove in flange shaft.
AG.
– Drive in flange shaft -1- using thrust piece - T40165- .

– Insert flange shaft.
• To secure flange shaft, flange differential lock must be disen‐
gaged.
– Screw two bolts into flange and counterhold flange shaft using
an assembly lever.
5. Oil seals 33
– Screw in securing bolt for flange shaft and tighten to specified

torque.
A - Commercially available 6 mm socket or hexagon key - V.A.G
1669- .
AG. Volkswagen AG d
agen o
– Install right drive shaft
olks⇒ Running gear, axles, steering;
w es n
ot g Rep.
yV
gr. 42 ; Drive shaft;
sed b Removing and installing drive shaft
ua
ran .
ri tee
ho
– Check gear
au oil in rear final drive ⇒ page 23 .
t or
ac
ss
Torque settings
ce
le
un
pt
an
d
itte
♦ ⇒ Rep. gr. 42 ; Drive shaft; Assembly overview - drive shaft
y li
rm
ab
pe
ility
ot
wit
, is n
Securing bolt for flange shaft 22 Nm
h re
hole
spec
es, in part or in w
5.2 Renewing left seal
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
♦ Drip tray for workshop hoist - VAS 6208- Prote AG.
♦ Puller - T10055-

satelettronica
wage
♦ Hexagon key - V.A.G 1669-y Vo lks es n
ot g
d b ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Removing
rrectne
– Disconnect left drive shaft, swing forwards and tie up. When
s
doing this, do not damage surface protection.

s o
cial p
f i
– Place drip tray for workshop hoist - VAS 6208- under rear final
nform
drive.
mer
atio
m

o
n
c
i
or
n thi
– Unscrew securing bolt for flange shaft. Screw two bolts into
te
sd
a
flange to do this. Counter flange shaft using an assembly lever.

iv
o
pr
cum
r
fo
Use a commercially available 6 mm socket or hexagon key -

en
ng
t.
yi
V.A.G 1669- as necessary.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Oil seals 35
Propshaft and rear final drive - Edition 01.2019 agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
Continued for all vehicles rise
d
nte
tho eo
u
– Screw thread adapter, e.g. Kukko 18–0 -A-, into flangessshaft
a ra
c
-1-.
ce
e
nl
pt
du
an
– Pull out flange shaft -1- using puller - T10055- and adapter -
itte
y li
T10055/3- .
erm
ab
ility
ot p
– Carefully drill a 4 mm hole into oil seal.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Screw self-tapping screw -2- into seal -1-.
l purpos
Note
nform
mercia
Do not screw in sheet metal screw too far to avoid damaging
at
om
io
bearing behind it.
n
c
in t
or
his
te
satelettronica
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Pull out seal -1- using puller - T10055- and adapter - cted agen
Prote AG.
T10055/2- .
– Remove any swarf from final drive.
Installing
– Lightly oil outer circumference of oil seal and half-fill space
between sealing lips -arrow- with grease .

– Drive in seal to stop with thrust piece - T10049- , being careful

not to cant seal.
– Clamp flange shaft in vice with protective jaw covers.

– Use new retaining ring -A- to press old retaining ring out of AG. Volkswagen AG d
agen
groove in flange shaft. Volksw
oes
not
by gu
d ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
satelettronica
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Vehicles without differential lock
t to the co
– Drive in flange shaft -1- using thrust piece - T40165- .
rrectness of i
– Insert flange shaft.
l purpos
• To secure flange shaft, flange differential lock must be disen‐
nform
gaged.
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Screw two bolts into flange and counterhold flange shaft using en
ng
t.
yi Co
an assembly lever. t. Cop py
rig
gh ht
– Screw in securing bolt for flange shaft and tighten to specified yri
p by
o Vo
torque.
c by lksw
cted agen
Prote AG.
Use a commercially available 6 mm socket or hexagon key -
V.A.G 1669- as necessary.
– Install left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 42 ; Drive shaft; Removing and installing drive shaft .
– Check gear oil in rear final drive ⇒ page 23 .
Torque settings
♦ ⇒ Rep. gr. 42 ; Drive shaft; Assembly overview - drive shaft
Securing bolt for flange shaft 22 Nm
5. Oil seals 37
5.3 Renewing input shaft seal

♦ Removal tool - VW 681-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
♦ Tapered roller bearing puller - T10055- ris ed
nte
ho eo
aut ra
ss c
ce
le
un
pt
satelettronica
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Counter-hold tool - 3145-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Locking fluid ⇒ Electronic parts catalogue (ETKA)
Removing
– Remove rear propshaft ⇒ page 56 .
– Remove anti-roll bar ⇒ Running gear, axles, steering; Rep.
gr. 42 ; Anti-roll bar; Removing and installing anti-roll bar .
– Screw counterhold - 3145- onto propshaft flange.
– Unscrew hexagon nut for propshaft flange.
– Pull off propshaft flange with puller - T10055- .

– Lever out oil seal with oil seal extractor lever - VW 681- .
Installing
– Lightly oil outer circumference of oil seal and half-fill space
between sealing lips -arrow- with grease .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Drive in new seal to stop with thrust piece - T50062- , being
s
ce
le
careful not to cant seal.

un
pt
an
d
itte
y li
– Insert propshaft flange.

erm
ab
ility
ot p
– Screw on new hexagon nut for propshaft flange.

wit
is n
h re
– Screw counterhold - 3145- onto propshaft flange.

ole,
spec
– Tighten hexagon nut ⇒ Item 12 (page 45) .

t to the co
– Install anti-roll bar ⇒ Running gear, axles, steering; Rep. gr.

42 ; Anti-roll bar; Removing and installing anti-roll bar .
rrectne
– Install rear propshaft ⇒ page 56 .

– Check fluid level of all-wheel drive coupling ⇒ page 25 .
ss o
Torque settings
cial p
f inform
mer
♦ ⇒ “8.1.2 Assembly overview - propshaft, long wheelbase”,

atio
page 52
om
n
c
♦ ⇒ “7.1 Assembly overview - all-wheel drive coupling”,

or
n thi
e
page 44
t
sd
iva
o
pr
cum
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Anti-roll bar;

r
fo
en
ng
Assembly overview - anti-roll bar

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Oil seals 39
6 Differential lock
⇒ “6.1 Function of differential lock”, page 40
⇒ “6.2 Components of differential lock”, page 40
⇒ “6.3 Removing and installing actuator for differential lock”, page
41
⇒ “6.4 Renewing bellows on rear final drive”, page 43
6.1 Function of differential lock

Installed as an option in the Transporter with 4 MOTION is a me‐
chanical rear axle differential lock.
The rear axle differential lock can be engaged at speeds of up to
45 km/h. Differential lock warning lamp - K81- in dash panel insert
indicates that rear axle differential lock is engaged.
Differential lock is engaged and disengaged with rear differential
lock switch - E121- . Differential lock control unit - J187- checks
whether conditions for engaging differential lock have been met.
If this is the case, all-wheel drive control unit - J492- engages lock
by means of differential lock control unit - J187- , differential lock
satelettronica
valve 1 - N125- and differential lock valve 2 - N126- .
For more information about the function, refer to ⇒ Self-study
programme No. 333 ; 4Motion with all-wheel drive coupling .
For information and safety notes on operation, refer to ⇒ General
notes on Transporter .
6.2 Components of differential lock
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Dash panel insert

2 - Differential lock warning
lamp - K81-
3 - Brake servo
4 - Differential lock valve 1 -
N125-
❑ Installation location: un‐
der front floor covering
5 - Differential lock valve 2 -
N126-
6 - Vacuum reservoir
7 - Control element
❑ On rear final drive
❑ with:
satelettronica
♦ Reed contact switch 1 for
differential lock - F360-
♦ Vacuum switch for rear dif‐
ferential lock - F363-
8 - All-wheel drive control unit
- J492-
. Volkswagen AG
⇒ page 50 swa
gen AG does
k not
Vol gu
by
9 - Differential locksedswitch - ara
nte
F237- thori
eo
au ra
c
10 - Differential
ss lock control unit - J187-
ce
le
un
pt
an
d
itte
y li
rm
ab
6.3 Removing and installing actuator for dif‐

pe
ility
ot
ferential lock
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
♦ Engine and gearbox jack - VAS 6931-

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
41
cted agen
Prote AG.
6. Differential lock
Removing
– Place engine and gearbox jack - VAS 6931- under final drive.
– Unscrew bolts -1-.
– Lower final drive, until propshaft rests slightly on anti-roll bar.
The propshaft and drive shaft remain bolted to the final drive.
satelettronica
– Disconnect connector -2- from actuator for differential lock
-1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Unscrew bolts -2-.

t to the co
– Pull vacuum hoses off actuator.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Detach bellows -1- from actuator for differential lock.
– Pull off retaining ring -2-.

– Pull pin -3- out of actuator for differential lock -1-.
– Remove actuator for differential lock -1- from final drive.
Installing
Torque settings
satelettronica
page 44
6.4 Renewing bellows on rear final drive

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
– Remove actuator for differential lock ⇒ page 41 .
rrectness of i
– Lever out bellows -1- using removal wedge - 3409- .

l purpos
Installing
nform
ercia
Install in reverse order of removal.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6. Differential lock 43
7 All-wheel drive coupling

⇒ “7.1 Assembly overview - all-wheel drive coupling”, page 44
⇒ “7.2 Checking function”, page 45
wage es n
⇒ “7.3 Removing and installing pump for all-wheel drive coupling”,
yV
olks ot g
ua
page 46 ise
d b ran
r tee
ho
⇒ “7.4 Removing and installing all-wheel drive coupling”,
sa
ut or
ac
page 48 s
ce
e
nl
pt
du
⇒ “7.5 Removing and installing control unit”, page 50
an
itte
y li
erm
ab
7.1 Assembly overview - all-wheel drive
ility
ot p
coupling
wit
, is n
h re
hole
All-wheel drive coupling is removed and installed with final drive
spec
es, in part or in w
in situ.
t to the co
rrectness of i
satelettronica
⇒ page 9
l purpos
2 - Filler plug
nform
ercia
❑ Renew filler plug seal af‐

ter removing
m
at
om
i
❑ 15 Nm
on
c
in t
or
3 - Drain plug
his
ate
do
riv
❑ Renew drain plug seal

p
cum
or
after removing
f
en
ng
t.
yi Co
❑ 30 Nm t. Cop py
rig
gh ht
4 - Actuator for differential lock yri
p by
o Vo
by c lksw
❑ Further information cted agen
Prote AG.
about differential lock
⇒ page 40
5 - Bolts
❑ For actuator of differen‐
tial lock
❑ 40 Nm
6 - All-wheel drive control unit
- J492-
⇒ page 50
7 - Bolts
❑ Qty. 2
❑ 10 Nm
8 - O-ring
❑ Moisten with high-per‐
formance oil for all-
wheel drive coupling ,
and insert
❑ Renew after all-wheel drive coupling has been removed
9 - Housing for all-wheel drive coupling
❑ Removing and installing all-wheel drive coupling ⇒ page 48
10 - Propshaft flange seal
Renewing ⇒ page 38

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
d
rise Propshaft and rear final drive
nte - Edition 01.2019
ho eo
aut ra
ss c
11 - Propshaft flange
ce
e
nl
pt
❑ Removing and installing ⇒ page 38
du
an
itte
y li
12 - Nut
erm
ab
ility
ot p
wit
, is n
❑ Secure with locking fluid
h re
hole
spec
❑ 210 Nm es, in part or in w
t to the co
13 - Bolts
❑ Qty. 4
❑ 50 Nm
rrectness of i
14 - O-ring
l purpos
❑ For all-wheel drive coupling pump - V181-
nf
ercia
❑ Qty. 2
orm
m
atio
om
n in
15 - All-wheel drive coupling pump - V181-
or c
thi
e
❑ Removing and installing ⇒ page 46

t
sd
iva
o
r
rp
cu
16 - Bolts
o
m
f
en
satelettronica
ng
❑ For all-wheel drive coupling pump - V181-

t.
yi Co
Cop py
❑ Qty. 2
t. rig
gh ht
yri by
❑ 10 Nm cop Vo
by lksw
cted agen
Prote AG.
7.2 Checking function
Note
All-wheel drive coupling is checked during a road test using Ve‐

hicle diagnosis and service information system - VAS 5052- .
WARNING
To avoid accidents, observe the

⇒ “1.2 Safety measures when using testers and measuring in‐
struments during a road test”, page 1 for measuring and road
tests.
– Checking function ⇒ Vehicle diagnostic tester Guided func-

tions .
Starting “Guided functions”:

– Switch on ignition.
– Touch “Guided functions” section/button on screen.
– Select one after the other on the display of vehicle diagnostic
tester:
♦ Brand
♦ Model
♦ Model year
♦ Version
♦ Engine code
♦ Confirm data entered.
7. All-wheel drive coupling 45

♦ 22 - All-wheel drive electronics

♦ 22 - Final control diagnosis
– Start final control diagnosis and proceed by following the in‐
structions on the display of vehicle diagnostic tester.
7.3 Removing and installing pump for all-

wheel drive coupling
♦ Used oil collector and extractor - VAS 6622A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
satelettronica
y li
erm
ab
ility
ot p
wit
, is n
Removing
h re
hole
spec
– Switch off ignition.
es, in part or in w
t to the co
under rear final drive.
rrectness of i
all-wheel drive coupling completely.
l purpos
– Screw in drain plug -arrow- with new seal and tighten to speci‐
fied torque.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
– Pull off stone deflector -1- from all-wheel drive coupling pump
co Vo
by lksw
cted agen
- V181- . Prote AG.

– Pull off electrical connector -arrow- for all-wheel drive coupling

pump - V181- from all-wheel drive control unit - J492- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Unclip cable retainer -2- on housing and lay wiring harness
wit
-1- aside.
, is n
h re
hole
– Unscrew bolts -3- for all-wheel drive coupling pump - V181- .
spec
es, in part or in w
t to the co
under rear final drive.
– Pull out all-wheel drive coupling pump from housing of all-
rrectness of i
wheel drive coupling.
satelettronica
l purpos
nf
ercia
orm
m
atio
om
Installing
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
– When installing removed all-wheel drive coupling pump again,

o
m
f
en
ng
renew O-rings -1- and -2-.

t.
yi Co
Cop py
– Thinly coat O-rings -1- and -2- with high-performance oil for
t. rig
gh ht
yri
all-wheel drive coupling .
p by
co Vo
by lksw
cted agen
– Push all-wheel drive coupling pump into housing for all-wheel
Prote AG.
drive coupling onto stop.
– Tighten bolts -3- ⇒ Item 16 (page 45) .

– Route wiring harness -1- on housing and clip in cable retainer
-2-.

– Fit electrical connector -arrow- for all-wheel drive coupling

pump on all-wheel drive control unit .
– Fill with high-performance oil for all-wheel drive coupling , and
check oil level in all-wheel drive coupling ⇒ page 25 .
Torque settings
page 44
7.4 Removing and installing all-wheel drive

coupling wage
e
olks s no
yV t gu
Special tools and workshop equipment required edb ara
ris nte
♦ Torque wrench - V.A.G 1331- tho eo
au ra
c
ss
ce
le
un
pt
satelettronica
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Used oil collector and extractor - VAS 6622A-
Removing
– Remove rear propshafts ⇒ page 56 .

– Remove anti-roll bar ⇒ Running gear, axles, steering; Rep.

gr. 42 ; Anti-roll bar; Removing and installing anti-roll bar .
under all-wheel drive coupling.
all-wheel drive coupling completely.
– Screw in new drain plug -arrow- with new seal and tighten
⇒ page 44 .
– Separate electrical connector -B- on all-wheel drive control

unit - J492- -A-.
satelettronica
Note
Do not pull off electrical connector -C-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
– Remove bolts -arrows- uth o
or
s a ac
– Pull out all-wheel drive coupling s-1- from rear final drive.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Installing
l purpos

nform
ercia
– Lightly oil new seal -arrow- with high performance oil for all-
wheel drive coupling and insert.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Insert all-wheel drive coupling -1- in rear final drive.

– Tighten bolts -arrows- ⇒ Item 13 (page 45) .
– Push electrical connector -B- onto all-wheel drive control unit

- J492- -A-.
Electrical connector -C- must also be pushed on.
– Install anti-roll bar ⇒ Running gear, axles, steering; Rep. gr.
42 ; Anti-roll bar; Removing and installing anti-roll bar .
– Install rear propshafts ⇒ page 56 .
satelettronica
– Pour fresh high performance oil for all-wheel drive coupling in
all-wheel drive coupling and check oil level ⇒ page 26 .
Torque settings
page 44
♦ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Anti-roll bar;
Assembly overview - anti-roll bar
7.5 Removing and installing control unit

Removing
wage es n
– Pull electrical connectors -B- and -C- off all-wheel yV
o drive control
lks ot g
unit -A-. ir se
d b ua
ran
o tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolts -arrows- for all-wheel drive control unit and re‐
rrectness of i
move all-wheel drive control unit -A-.

l purpos
Installing
Install in reverse order of removal.
nform
ercia
Torque settings
m
a
com
tio

n in
r
page 44
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

8 Propshaft
⇒ “8.1 Assembly overview - propshaft”, page 51
⇒ “8.2 Removing and installing propshaft”, page 53
⇒ “8.3 Removing and installing centre propshaft bearing”,
page 59
⇒ “8.4 Checking constant velocity joint”, page 64
8.1 Assembly overview - propshaft

⇒ “8.1.1 Assembly overview - propshaft, short wheelbase”, page
51
⇒ “8.1.2 Assembly overview - propshaft, long wheelbase”,
page 52
AG. Volkswagen
8.1.1 Assembly
Vol
ksw
agen overviewAG- dpropshaft,
oes
not short
e wheelbase
by gu
d aran
ris te
tho eo
s au ra
c
s
satelettronica
Note
ce
le
un
pt
an
d
itte
y li
♦ Support the propshaft or tie it to the body to prevent over-
erm
ab
bending of the joint when repairing a section of the propshaft.

ility
ot p
wit
is n
♦ Depending on model variant and equipment, there are 2 dif‐

h re
ole,
ferent versions of propshaft. Note allocation ⇒ Electronic parts

spec
catalogue (ETKA) .
t to the co
♦ Transport and propshaft extended only.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8. Propshaft 51
Transporter 2016 ➤ n AG. Volkswagen AG do
wage es n
Propshaft and rear final drive - Edition 01.2019 y Volks ot g
d b ua
e ran
ris tee
1 - Gearbox utho or
a ac
ss
2 - Heat shield
ce
le
un
pt
an
3 - Packing plate
d
itte
y li
rm
ab
4 - Flange bolt
pe
ility
ot
wit
, is n
h re
❑ M8: 30 Nm +90°
hole
spec
❑ M10: 50 Nm +90°
es, in part or in w
t to the co
5 - Front propshaft
rrectness of i
⇒ page 53
l purpos
6 - Nut
❑ For heat shield
nform
ercia
❑ Qty. 3
m
a
com
tio
❑ 20 Nm
n in
r
te o
thi
s
iva
do
satelettronica
r
rp
c
um
fo
⇒ page 9
en
ng
t.
yi Co
op
8 - Rear propshaft
C py
t. rig
gh ht
yri
p by
co Vo
by lksw
⇒ page 56 Prote
cted AG.
agen
9 - Centre bearing
⇒ page 59
❑ Align free of tension
10 - Bolt
❑ For centre propshaft
bearing
❑ 20 Nm +90°
8.1.2 Assembly overview - propshaft, long

wheelbase
Note

♦ Depending on model variant and equipment, there are 2 dif‐
ferent versions of propshaft. Note allocation ⇒ Electronic parts
catalogue (ETKA) .

AG. Volkswagen AG d
1 - Gearbox agen oes
olksw not
y V gu
d b ara
2 - Heat shield orise nte
th eo
u ra
3 - Packing plate ss a c
ce
le
4 - Flange bolt
un
pt
an
d
itte
y li
rm
ab
❑ M8: 30 Nm +90° pe
ility
ot
wit
❑ M10: 50 Nm +90°
, is n
h re
hole
5 - Centre bearing
spec
es, in part or in w
t to the co
⇒ page 59
❑ Align free of tension
rrectness of i
6 - Bolt
l purpos
❑ For centre propshaft

bearing
nform
ercia

❑ 20 Nm +90°
m
a
com
tion in
7 - Front propshaft
satelettronica
r
te o
thi
s
iva
do
⇒ page 53
r
rp
cum
fo
en
g
8 - Nut
n
t.
yi Co
op
❑ For heat shield
C py
t. rig
gh ht
yri
❑ Qty. 3 p by
co Vo
by lksw
cted
agen
Prote AG.
❑ 20 Nm
⇒ page 9
10 - Rear propshaft
⇒ page 56
11 - Holder
❑ Boot
12 - Bolts
❑ For bracket
❑ 20 Nm +90°
8.2 Removing and installing propshaft

⇒ “8.2.1 Removing and installing front propshaft”, page 53
⇒ “8.2.2 Removing and installing rear propshaft”, page 56
8.2.1 Removing and installing front propshaft

8. Propshaft 53
AG. Volkswagen AG d
agen oes
♦ Torque wrench - V.A.G 1331- olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Bit insert - T10099-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
satelettronica
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
♦ Counter-hold tool - T10172A-
lksw
cted agen
Prote AG.
Note
♦ Remove and install propshaft with the help of a second me‐

chanic.
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
Removing
♦ Before removing, mark positions of all parts relative to each
other. Reinstall in same position to prevent damage through
imbalance causing rumbling noises.
♦ A two pillar lifting platform must be used when working on the
propshaft.
Note
The counterhold tool - T10172A- can be used as an option to

counterhold the propshaft.
– Apply handbrake and engage first gear.

– Raise vehicle.
– Check whether a mark (coloured spot) is present on front
propshaft and on output flange of bevel box.

– If no such mark can be found, mark position of bevel box output

flange -arrow A- relative to propshaft constant velocity joint
-arrow B- with coloured marks.
– Check whether a mark (coloured spot) is present on front and
rear propshafts.
– If no such marks can be found, mark position of parts

-arrow A- and -arrow B- relative to each other withn Acoloured
G. Volkswagen AG d
marks. olks
wage oes
no
yV t gu
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
satelettronica
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew lower 3 connecting bolts on front propshaft/rear prop‐
shaft; use bit - T10099- if necessary.
– Unscrew lower 3 securing bolts from front propshaft/bevel box.
rrectness of i
– Lower vehicle.
l purpos
– Release handbrake and shift gearbox to neutral.
nform
ercia
– Raise vehicle and turn propshaft 180°.

m
– Lower vehicle. a
com
tion in
r

te o
thi
s
iva
do
– Raise vehicle.
r
rp
cum
fo
– Unscrew remaining securing bolts for front propshaft.

en
ng
t.
yi Co
Cop py
ht. rig
– If fitted, unscrew bolts for centre propshaft bearing -arrows-. rig ht
py by
co Vo
by lksw
– Remove propshaft with aid of second mechanic. cted agen
Prote AG.
8. Propshaft 55
Installing
– If relevant, tighten new bolts for centre propshaft bearing
-arrows- ⇒ page 51 .
• Align centre propshaft bearing free of tension.
Always renew securing bolts for propshaft.
– Ensure that marks on flange of front and rear propshafts

-arrow A- and -arrow B- align.
satelettronica
– Ensure that marks on output flange/bevel box -arrow A- and
on constant velocity joint/propshaft -arrow B- align.
– First screw all securing bolts into constant velocity joints.
agen
AG. Volkswagen AG d
o w es n
olks ot g
– After screwing in all securing bolts by hand, tightenby to specified
V ua
ed ran
torque ⇒ page 51 . or
is tee
th or
au
Torque settings ss
ac ce
e
nl
♦ ⇒ “8.1 Assembly overview - propshaft”, page 51

pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
8.2.2 Removing and installing rear propshaft

es, in part or in w
t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Bit insert - T10099-
Note
♦ Remove and install propshaft with the help of a second me‐

chanic.
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
satelettronica
Removing
Note
The counterhold tool - T10172A- can be used as an option to

counterhold the propshaft.
wage
– Apply handbrake o and engage first gear.
lks es n
ot g
byV ua
ed ran
– Raise vehicle.
horis tee
ut or
a a
– Checkss whether a mark (coloured spot) is present on frontcand
rear propshafts.
ce
le
un
pt
an
d
itte
– If no such marks can be found, mark position of parts

y li
rm
ab
-arrow A- and -arrow B- relative to each other with coloured

pe
ility
marks.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Ensure that marks on constant velocity joint/propshaft

m
-arrow A- and on output flange/rear final drive -arrow B- align.

com
tion in
– If no marking can be found, mark position of constant velocity

r
te o
thi
joint -arrow A- relative to rear final drive -arrow B- using col‐

s
iva
do
oured marks.
r
rp
cum
fo
en
ng
t.
yi Co
Caution
Cop py
t. rig
gh ht
pyri by
Rear propshaft must not be allowed to hang. Over-flexing will
co Vo
by lksw
cted agen
damage the joint. Prote AG.
8. Propshaft 57
– If fitted, unscrew bolts -2- and remove bracket -1-.
– Unscrew lower 3 connecting bolts on front propshaft/rear prop‐

shaft; use bit - T10099- if necessary.
– Unscrew lower 3 securing bolts from rear propshaft/input
flange of final drive.
– Lower vehicle.
– Release handbrake and shift gearboxolto
kswneutral.
age es n
ot g
V
by ua
satelettronica
– Raise vehicle and turn propshaft
ris 180°.
ed ran
tee
tho or
– Lower vehicle. ss au ac
ce
e

nl
pt
du
an
itte
y li
– Raise vehicle.
erm
ab
ility
ot p
– Unscrew remaining securing bolts for rear propshaft.
wit
, is n
h re
hole
– If fitted, unscrew bolts for centre propshaft bearing -arrows-.
spec
es, in part or in w
– Remove propshaft with aid of second mechanic.

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
Installing
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
op py
– If relevant, tighten new bolts for centre propshaft bearing
. C rig
ht ht
rig
-arrows- ⇒ page 51 . py by
co Vo
by lksw
cted agen
• Align centre propshaft bearing free of tension. Prote AG.
Always renew securing bolts for propshaft.

AG. Volkswagen AG d
agen oes
ksw not
by Vol
Transporter gu2016 ➤
ara
d
oPropshaft
rise and rear final drive - Edition 01.2019
nte
eo
th
au ra
s c
– Ensure that marks on constant velocity joint/propshaft s
ce
e
-arrow A- and on propshaft flange/rear final drive -arrow B-
nl
pt
du
an
align.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Ensure that marks on flange of front and rear propshafts l purpos
-arrow A- and -arrow B- align.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
satelettronica
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– If relevant, screw on bracket -1- with new bolts -2-

⇒ Item 12 (page 53) .
– First screw all securing bolts into constant velocity joints.
– After screwing in all securing bolts by hand, tighten to specified
torque ⇒ page 51 .
Torque settings
♦ ⇒ “8.1 Assembly overview - propshaft”, page 51
8.3 Removing and installing centre prop‐

shaft bearing
♦ Pliers - 3340-
8. Propshaft 59
♦ -2- Puller - Kukko 18-2- (VAS 251 419)
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ -3- Splitter - Kukko 17-2- (VAS 251 411)
ility
ot p
wit
, is n
♦ Drift sleeve - VW 244 B-
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
♦ Allocate grease for constant velocity joint using ⇒ Electronic

t
sd
iva
parts catalogue (ETKA) .

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
Note
C py
ht. rig
rig ht
py by
co Vo
♦ The centre propshaft bearing can be replaced as an individual
by lksw
cted agen
Prote
part and is available as a repair kit ⇒ Electronic parts cata‐
AG.
logue (ETKA) .
♦ Before dismantling, mark positions of all parts relative to each
other. Assemble in same position; otherwise an imbalance
may be created which causes damage to bearing and rum‐
bling noises.
Removing
– Remove propshaft with centre propshaft bearing ⇒ page 53 .
– Prise out cap with a screwdriver.

– Remove seal -arrow-. AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Drive down joint protective boot with a brass or copper drift.
rrectness of i
l purpos
nform
mercia
at
satelettronica
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
– Remove retaining ring. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Mark installation position of constant velocity joint, and pull off

constant velocity joint -A-.
1- Splitter - Kukko 17-2- (VAS 251 411)
2- Puller - Kukko 18-2- (VAS 251 419)
• Fit splitter with the plane surface -arrow- facing towards con‐
stant velocity joint -A-.
• Position the splitter close to the propshaft, so that the entire
constant velocity joint is enclosed in the splitter.
Note
Clean and check constant velocity joint as necessary

⇒ page 64 .
8. Propshaft 61
– Open clamp for boot -1- using pliers - 3340- .

– Then, pull boot off propshaft.
– Mark installation position of centre propshaft bearing, and pull

off centre propshaft bearing -A- together with shim -B-.
1- Splitter - Kukko 17-2- (VAS 251 411)
2- Puller - Kukko 18-2- (VAS 251 419)
• Fit splitter with the plane surface -arrow- facing towards centre
propshaft bearing -A-.
satelettronica
• Position the splitter close to the propshaft, so that the entire
centre propshaft bearing is enclosed in the splitter.
Installing
• The high collar -arrow- of the centre propshaft bearing -1-
faces towards propshaft -2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
– Drive on centre propshaft bearing to stop without canting using

ab
pe
ility
drift sleeve - VW 244 B- .

ot
wit
, is n
– Then, use drift sleeve - VW 244 B- to drive on shim to stop on

h re
hole
centre propshaft bearing.

spec
es, in part or in w
– Push boot with clamp onto propshaft.

t to the co
Propshaft, boot and contact surface of cap must be free of grease!

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

• The chamfer on the ball hub -arrow A- and on the ball race
-arrow B- of the constant velocity joint -1- face towards prop‐
shaft -2-.
– Drive on constant velocity joint to stop using drift sleeve - VW

244 B- .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Insert new circlip, and make sure it is properly seated. s
ce
e
nl
pt
du
– Grease constant velocity joint with grease for constant velocity an

itte
joint ⇒ Electronic parts catalogue (ETKA) . y li

erm
ab
ility
ot p
– Insert cap seal of boot. wit

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Use bolts to align cap -arrows- relative to bolt holes.

nf
ercia
The alignment must be very precise because it is not possible to

orm
repeat the alignment after driving on.

m
atio
om
n in
– Drive on cap with a plastic hammer.

or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
8. Propshaft 63
– Close clamp for boot using pliers - 3340- .

– Remove any excess grease for constant velocity joint , and
clean contact surface of seal.
– Insert seal -arrow- into constant velocity joint.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Use bolts to align cap for constant velocity joint
rise -arrows- rela‐
d b ara
nte
tive to bolt holes. utho eo
ra
s a c
The alignment must be very accurate. No further alignment is s
ce
le
possible once the part has been hammered on.

un
pt
an
d
itte
y li
– Drive on cap for constant velocity joint using a plastic hammer.
rm
ab
pe
ility
– Remove any excess grease for constant velocity joint .
ot
wit
, is n
h re
– Install propshafts ⇒ page 53 .
hole
spec
Torque settings
es, in part or in w
t to the co
♦ ⇒ “8.1 Assembly overview - propshaft”, page 51 rrectness of i
8.4 Checking constant velocity joint

l purpos
Dismantle the constant velocity joint, if:

♦ Grease is to be renewed
nform
ercia
♦ It is soiled
m
a
com
tion in
♦ Contact surfaces and balls need to be checked for wear.

r
te o
thi
s
iva
Dismantling
do
r
rp
cum
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
Ball hub and joint part are matched and must be marked before cop Vo
by lksw
dismantling. Do not interchange race allocation.
cted agen
Prote AG.
– Swing ball hub and ball cage.

– Press out joint part in direction of -arrow-.

– Press balls out of cage.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Tip ball hub out of ball cage via ball track -arrows-.
ility
ot p
wit
, is n
– Check joint body, ball hub, ball cage and balls for scoring (pit‐
h re
ting) and traces of seizing.
hole
spec
es, in part or in w
t to the co
Note
Load change jolts are an indication of excessive circumferential
rrectness of i
satelettronica
backlash in the joint. In such cases, renew the joint. Smoothing
l purpos
and tracks left by the balls are no cause for joint renewal.
nform
mercia
at
om
Assembling
ion
c
in t
or
– Insert hub into cage via the two chamfers. The hub can be
his
ate
installed in any position. Press balls into cage.

do
priv
cum
or
– Insert hub with cage and balls perpendicular to joint body.

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ When inserting, observe that the greater space -a- on joint

piece always lies together with the lesser space -b- on the hub
after being swung in.
♦ Chamfer on inner circumference of ball hub (splines) must
face propshaft.
8. Propshaft 65
– Swing ball hub into position. Do so by swinging hub far enough

out of cage -arrows- that balls have same spacing as races.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Swivel in hub with balls by applying firm pressure to cage
-arrow-.
satelettronica
rrectness of i
Checking function of constant velocity joint:
l purpos
The constant velocity joint is correctly assembled if the ball hub

can be moved by hand backwards and forwards over its entire
range of axial movement.
nf
ercia
orm
– Press specified quantity of grease into joint body.
m
atio
om
n in
Allocate grease according to ⇒ Electronic parts catalogue (ET‐
or c
KA) .
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Workshop Manual Transporter 2016 11-29

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

Workshop Manual Transporter 2016 11-29

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

Copyright © 2019 Volkswagen AG, Wolfsburg D4B805652B5

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 Checking fluid level in all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.1 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thi 34

5.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7 All-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

00 – Technical data byV gu

⇒ “1.1 Safety measures when working on vehicles with a start/

⇒ “1.2 Safety measures when using testers and measuring in‐

struments during a road test”, page 1

with start/stop system.

♦ In vehicles with an activated start/stop system (indicated

♦ When working on the vehicle, always make sure that the

Vehicles with dual clutch gearbox - risk of injury and accident

Observe the following if test and measuring instruments are re‐

Risk of accident due to distraction and inadequate securing of

To prevent personal injury and damage to or destruction of elec‐

Risk of irreparable damage to electronic components when AG. Volkswagen AG d

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .

2 Rep. gr.00 - Technical data

2.1 Identification of final drive

3.1 General repair instructions

is filled with “high performance oil for all-wheel drive coupling”.

Do not mix »additives« in oil.

Oil which has been drained out cannot be added again.

Use caution when handling oil. Dispose of used oil properly.

One drop of oil will contaminate 1,000 litres of water.

4 Rep. gr.00 - Technical data

♦ Heat inner races to about 100° C before installing.

3.2 Gaskets and seals

3.3 Nuts and bolts

housings in diagonal sequence.

♦ Delicate parts in particular must not be canted. Loosen and

tighten in stages in a diagonal sequence.

♦ Ensure with threaded connections that contact surfaces as

♦ Use a thread chaser to clear residual locking fluid from all

threaded holes into which self-locking bolts are to be screwed.

Otherwise there is a danger of bolts shearing when subse‐

quently being removed.

3.4 Notes on performance test

Be careful when working with oil. Dispose of drained oil ac‐

6 Rep. gr.00 - Technical data

4.1 Allocation final drive - engine

4.1.1 Allocation final drive - engine, dual clutch gearbox

Rear final drive 0CD

Gearbox type 7-speed dual clutch gearbox 0BT

Codes QUE RMF RMG

Engine 2.0 l - 110 kW 2.0 l - 150 kW 2.0 l - 150 kW

turbo diesel turbo diesel turbo diesel

Refer to ⇒ Electronic parts catalogue (ETKA) for following data:

♦ Allocation of drive shaft flanges

♦ The allocation of the manual gearbox

Gearbox type 6-speed manual gearbox 0A5

Rear final drive 0CD

Engine 2.0 l - 103 kW 2.0 l - 150 kW 2.0 l - 150 kW

8 Rep. gr.00 - Technical data

39 – Final drive - differential

1.1 Removing and installing final drive