00 GENERAL, TECHNICAL DATA

Transcription

1 00 GENERAL, TECHNICAL DATA DRIVETRAIN GUIDE REAR DIFFERENTIAL Rear Final Drive Fig. 1: Drivetrain Guide, Overview 1 - Transfer case Transfer case, removing and installing --> Differential, removing and installing 2 - Drive shafts

2 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

3 Fig. 3: Code Letters And Date Of Manufacture Of Transfer Case Example GJJ 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 > Touareg > Engine 4.2 L kw 5.0 L L -162 kw 230 kw Turbo-Diesel Transmission housing extension length mm mm Capacities 0.85 liters Transfer case 0AD Code letters FKC GFG GFH Application Model Touareg > Touareg > Touareg > Engine 3.2 L -162 kw 4.2 L kw 4.9 L kw Turbo- Diesel 3.2 L -162 kw Transmission housing extension length mm mm mm Capacities 0.85 liters Transfer case OAD Code letters GJJ GJK

4 Application Model Touareg > Touareg > Engine 4.2 L kw 5.0 L L -162 kw 230 kw Turbo-Diesel Transmission housing extension length mm mm Capacities 0.85 liters Transfer case 0AD Code letters GJL GTM Application Model Touareg > Touareg > Engine 3.2 L -162 kw 5.0 L kw Turbo- Diesel Transmission housing extension length mm mm Capacities 0.85 liters Transfer case 0AD Code letters GTN GTP HCH Application Model Touareg > Touareg > Touareg > Engine 3.2 L -162 kw 3.2 L 3.2 L -162 kw 3.2 L 5.0 L kw kw kw Turbo-Diesel Transmission housing extension length mm mm mm Capacities 0.85 liters Transfer case OAD Code letters HPW HPX Application Model Touareg > Touareg > Engine 5.0 L kw Turbo- Diesel 5.0 L kw Turbo- Diesel Transmission housing extension length mm mm Capacities Transfer case OAD Code letters HMX Application Model Touareg > Engine 3.2 L -177 kw Transmission housing extension length mm Capacities 0.85 liters Transfer case 0AD Code letters HXB HXE HXA Application Model Touareg > Touareg > Touareg > Engine 5.0 L kw 3.2 L -177 kw 4.2 L -228 kw 4.2 L

5 Turbo-Diesel -257 kw Transmission housing extension length mm mm mm Capacities 0.85 liters Transfer case 0AD Code letters HXC FKF Application Model Touareg > Touareg > Engine 3.2 L -177 kw 3.2 L -177 kw Transmission housing extension length mm mm Capacities 0.85 liters Transfer case 0AD Code letters FKG FKF Application Model Touareg > Touareg > Engine 3.2 L -177 kw 3.2 L -177 kw Transmission housing extension length mm mm Capacities 0.85 liters FRONT FINAL DRIVE IDENTIFICATION Front final drive identification The front final drive 0AA is allocated to the automatic transmission 09D. Code letters --> Code letters, transmission allocation, gear ratios, capacities. Front final drive identification, location Location on front final drive - arrow -. Fig. 4: Location On Front Final Drive

6 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 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 Front final drive 0AA Code letters FKK FKM FKN Application Model Touareg > Touareg > Touareg > Engine 4.2 L 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 = : 10 = :10 = Capacities 1.0 liters Drive shaft flange dia. 114 mm 114 mm 114 mm Electromechanical differential lock Without Without Without Front final drive 0AA Code letters FKQ FLH FLJ Application Model Touareg > Touareg > Touareg > 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 = : 10 = : 9 = Capacities 1.0 liters

7 Drive shaft flange dia. 114 mm 114 mm 114 mm Electromechanical differential lock Without With With Front final drive 0AA Code letters FVX FVZ GFA Application Model Touareg > Touareg > Touareg > Engine 5.0 L kw Turbo-Diesel 4.2 L kw 5.0 L kw Turbo-Diesel Gear ratio: Z 1 : Z 2 Final drive 36 : 11 = : 10 = : 11 = Capacities 1.0 liters Drive shaft flange dia. 122 mm 114 mm 122 mm Electromechanical differential lock Without Without Without Front final drive 0AA Code letters GFB GLZ Application Model Touareg > Touareg > Engine 3.2 L -162 kw 3.2L L kw TurbokW Diesel Gear ratio: Z 1 : Z 2 Final drive 41 : 9 = : 11 = Capacities 1.0 liters Drive shaft flange dia. 114 mm 122 mm Electromechanical differential lock Without Without Front final drive 0AA Code letters GMC GMN GNJ Application Model Touareg > Touareg > Touareg > Engine 3.2 L -162 kw 3.2 L 4.2 L -228 kw 4.9 L kw -177 kw Turbo-Diesel Gear ratio: Z 1 : Z 2 Final drive 41 : 9 = : 9 = : 11 = Capacities 1.0 liters Drive shaft flange dia. 114 mm 122 mm 122 mm Electromechanical differential lock Without Without Without Front final drive OAA Code letters GNL GNM Application Model Touareg > Touareg > Engine 3.2 L kw 4.5 L kw 3.2 L -162 kw 3.2 L -177 kw Gear ratio: Z 1 : Z 2 Final drive 41 : 10 = : 9 = Capacities 1.0 liters

8 Drive shaft flange dia. 114 mm 114 mm Electromechanical differential lock Without Without REAR FINAL DRIVE IDENTIFICATION Rear final drive identification The rear final drive 0AB/0AC is allocated to the automatic transmission 09D. Code letters --> Code letters, transmission allocation, gear ratios, capacities. 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.

9 Fig. 7: Code Letters And Date Of Manufacture Of Rear Final Drive Example FKY 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 Rear final drive 0AB/0AC Code letters FKS FKU FKV Application Model Touareg > Touareg > Touareg > Engine 4.2 L -228 kw 3.2 L -162 kw 3.2 L 4.2 L -228 kw kw 3.2 L kw Gear ratio: Z 2 : Z 1 Final drive 37 : 10 = : 10 = : 10 = Capacities 1.25 liters Drive shaft flange dia. 118 mm 112 mm 118 mm Electromechanical differential lock Without Without Without Rear final drive 0AB/0AC Code letters FKW FLM

10 Application Model Touareg > Touareg > Engine 3.2 L -162 kw 3.2 L -162 kw Gear ratio: Z 2 : Z 1 Final drive 41 : 9 = : 10 = Capacities 1.25 liters 1.6 liters Drive shaft flange dia. 112 mm 112 mm Electromechanical differential lock Without With Rear final drive 0AB/0AC Code letters FLN FLP Application Model Touareg > Touareg > Engine 4.2 L kw 3.2 L -162 kw Gear ratio: Z 2 : Z 1 Final drive 41 : 10 = : 9 = Capacities 1.6 liters Drive shaft flange dia. 118 mm 112 mm Electromechanical differential lock With With Rear final drive 0AB/0AC 0AB/0AC Code letters FLT FWC FWG Application Model Touareg > Touareg > Touareg > Engine 3.2 L kw L kw 4.2 L kw L -228 kw Turbo-Diesel Gear ratio: Z 2 : Z 1 Final drive 41 : 9 = : 11 = : 10 = 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. Rear final drive 0AB/0AC Code letters FWH GFC GFD Application Model Touareg > Touareg > Touareg > Engine 5.0 L kw Turbo-Diesel 3.2 L -162 kw 5.0 L kw Turbo-Diesel Gear ratio: Z 2 : Z 1 Final drive 36 : 11 = : 9 = : 11 = Capacities 1.6 liters 1.25 liters 1.25 liters Drive shaft flange dia. 118 mm 112 mm 118 mm Electromechanical differential lock With Without Without Rear final drive Code letters 0AB/0AC GLP

11 Application Model Touareg > Engine 3.2 L -162 kw 3.2 L -177 kw Gear ratio: Z 2 : Z 1 Final drive 39 : 10 = Capacities Drive shaft flange dia. Electromechanical differential lock 1.25 liters 112 mm Without Rear final drive 0AB/0AC Code letters GLQ GLR GLS Application Model Touareg > Touareg > Touareg > Engine 4.2 L -228 kw 3.2 L -162 kw 3.2 L 5.0 L kw -177 kw Turbo-Diesel Gear ratio: Z 2 : Z 1 Final drive 41 : 10 = : 9 = : 11 = Capacities 1.25 liters Drive shaft flange dia. 118 mm 112 mm 118 mm Electromechanical differential lock Without Without Without Rear final drive 0AB/0AC Code letters GMP GMQ Application Model Touareg > Touareg > Engine 4.2 L -228 kw 4.2 L -228 kw Gear ratio: Z 2 : Z 1 Final drive 41 : 9 = : 9 = Capacities 1.25 liters 1.6 liters Drive shaft flange dia. 118 mm 118 mm Electromechanical differential lock Without With Rear final drive 0AB/0AC Code letters GNN HLQ Application Model Touareg > Touareg > Engine 5.0 L kw Turbo- Diesel 5.0 L kw Turbo- Diesel Gear ratio: Z 2 : Z 1 Final drive 36 : 11 = : 11 = Capacities 1.6 liters 1.6 liters Drive shaft flange dia. 118 mm 118 mm Electromechanical differential lock With With Rear final drive 0AB/0AC Code letters HLU HLV Application Model Touareg > Touareg > Engine 3.2 L -177 kw 4.2 L L -162 kw 3.2 L -177

12 kw kw Gear ratio: Z 2 : Z 1 Final drive 41 : 09 = : 09 = Capacities 1.6 liters Drive shaft flange dia. 118 mm 112 mm Electromechanical differential lock With With Rear final drive 0AB/0AC Code letters FLA GLV Application Model Touareg > Touareg > Engine 3.2 L -177 kw 3.2 L -177 kw Gear ratio: Z 2 : Z 1 Final drive 41 : 09 = : 09 = Capacities 1.6 liters Drive shaft flange dia. 112 mm 112 mm Electromechanical differential lock Without Without Rear final drive 0AB/0AC Code letters FLA JAJ GLV Application Model Touareg > Touareg > Touareg > Engine 3.2L kw 5.0 L kw 3.2L kw Turbo-Diesel Gear ratio: Z 2 : Z 1 Final drive 41 : 09 = : 09 = : 09 = Capacities 1.6 liters 1.6 liters 1.6 liters Driveshaft flange dia. 112 mm 114 mm 112 mm Electromechanical differential lock Without With Without Rear final drive 0AB/0AC Code letters JLP JLQ Application Model Touareg > Touareg > Engine 5.0 L kw Turbo- Diesel 5.0 L kw Turbo- Diesel Gear ratio: Z 2 : Z 1 Final drive 36 : 11 = : 11 = Capacities 1.6 liters 1.6 liters Driveshaft flange 118 mm 118 mm Electromechanical differential lock Without With Rear final drive 0AB/0AC Code letters JLP JLQ Application Model Touareg > Touareg > Engine 5.0 L kw Turbo- Diesel 5.0 L kw Turbo- Diesel

13 Gear ratio: Z 2 : Z 1 Final drive 36 : 11 = : 11 = Capacities 1.6 liters 1.6 liters Driveshaft flange dia. 118 mm 118 mm Electromechanical differential lock Without With Rear final drive 0AB/0AC Code letters HEX JMB Application Model Touareg > Touareg > Engine 3.2 L -177 kw 4.2 L -257 kw Gear ratio: Z 2 : Z 1 Final drive 41 : 09 = : 10 = Capacities 1.6 liters 1.6 liters Driveshaft flange dia. 118 mm 118 mm Electromechanical differential lock With With 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.

14 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 Volkswagen Touareg 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 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.

15 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 Faultfinding", "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

16 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 E Differential motor V253 Removing and installing --> Differential motor V253, removing and installing

17 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 F 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

18 Fig. 12: Location Of Transfer Case Operating Unit E473 The transfer case operating unit E is located in shift cover 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

19 Fig. 14: Location Of Closed Throttle Position (CTP) Switch F60 The closed throttle position (CTP) switch F is located in the area of the shift cover with switching rockers on the manual transmission 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 at differential control module J646 and, if equipped, connector - 2 -at

20 transmission control module J217. Remove bolt 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 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 into recesses of seat frame. Fasten bolt to 8 Nm. Connect Ground (GND) terminal connector to battery and perform work sequences after connecting battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL.

21 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 A/7 Lifting tackle 2024 A Thrust pad 3062 Transmission support 3282

22 Adjustment plate 3282/37 Fig. 19: Identifying Special Tools - Differential, Removing And Installing (2 Of 2) Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Engine/transmission jack V.A.G 1383/A Grease for clutch disc shaft splines G Transfer case, removing Raise vehicle.

23 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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.

24 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.

25 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 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.

26 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.

27 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 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.

28 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. Check gear oil level in transfer case --> Gear oil level in transfer case, checking. Install exhaust system -->. Tightening torques 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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 Transfer case to transmission Damper to transfer case 45 Nm 32 Nm Console to transfer case, console to transmission and transmission support to structure. Routing of breather line on transfer case

29 Fig. 29: Routing Of Breather Line On Transfer Case The breather line for the transfer case runs over the transfer case and manual transmission to coolant hose The breather line is clipped into the retainer on the transfer case and retainer 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

30 Fig. 30: Identifying Special Tools - Transmission Carrier And Console, Removing And Installing Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 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.

31 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.

32 Fig. 33: Removing Bolts For Transmission Support From Transfer Case Console 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.

33 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 M8 x 35 Bolts M8 x Nm 20 Nm Transmission carrier to structure Always replace bolts Bolts M10 x 80 * See note 50 Nm plus an additional 90 1 / 4 turn *Always replace bolts Vehicles 10-cylinder engine

34 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 M8 x 35 Bolts M8 x Nm 20 Nm Transmission carrier to structure Always replace bolts Bolts M10 x 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

35 Fig. 37: Identifying Special Tools - Bonded Rubber Bushing In Transmission Carrier, Replacing Special tools, testers and auxiliary items required 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.

36 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.

37 Fig. 40: Aligning Bonded Rubber Bushing To Transmission Carrier, Using Assembly Tool T10214 Align bonded rubber bushing to transmission carrier, using assembly tool T 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 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

38 Gear oil level in transfer case, checking Transmission oil specification --> Code letters, transmission allocation, gear ratios, capacities Special tools, testers and auxiliary items required Fig. 42: Torque Wrench V.A.G 1331 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 -.

39 Top off oil to lower edge of filler hole. Insert new plug - arrow - and fasten. Oil filler plug Tightening torque: 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)

40 Holding fixture VW 313 Pressure plate VW 402 Punch VW 408 A Holding fixture VW 540 Slide hammer VW 771 Pulling hook VW 771/37 Fig. 45: Identifying Special Tools - Seals For Output Flange/Driveshaft And Differential Motor, Removing And Installing (2 Of 3) Special tools, testers and auxiliary items required Thrust pad

41 Tube Thrust pad 3062 Torque wrench V.A.G 1331 Torque wrench V.A.G Kukko 17/2 Separating device Fig. 46: Identifying Special Tools - Seals For Output Flange/Driveshaft And Differential Motor, Removing And Installing (3 Of 3) Special tools, testers and auxiliary items required Thrust plate T10185 Thrust plate T10203

42 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

43 Securing --> Fig. 69 Insert with Loctite O-ring Always replace Insert with gear oil --> Fig 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

44 Always replace Removing --> Fig. 65 Installing --> Fig. 68 Securing --> Fig. 69 Insert with Loctite O-ring Always replace Insert with gear oil --> Fig 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 V Alignment bushing Qty. 2 For aligning differential motor on transfer case 16 - Differential motor V253

45 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 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 G Seal Always replace 26 - Oil filler plug, 20 Nm Always replace 27 - Bolt, 32 Nm

46 28 - Vibration damper Not in all transmissions Observe installed location --> Fig 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

47 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

48 Fig. 52: Driving In Oil Seal For Output Flange/Rear Driveshaft Fill area between sealing lip and dust lip halfway with sealing grease G 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

49 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 Fill area between sealing lip and dust lip halfway with sealing grease G A1. 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

50 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 is malfunctioning, the Oil Temperature Sensor (with sealing ring - 3 -) is replaced by a screw plug - 1 -with sealing ring

51 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 for differential motor connector. Pivot 10-pin connector out of retainer Fig. 60: Identifying Engine Oil Temperature Sensor Wiring Harness & 10-Pin Connector The wires, pins and of 10-pin connector must be removed using appropriate ejection tool from wiring harness repair kit VAS Remove wiring harness for engine oil temperature sensor. Close off wire openings of terminals and in 10-pin connector. Input shaft seal, replacing

52 Fig. 61: Identifying Special Tools - Input Shaft Seal, Replacing Special tools, testers and auxiliary items required Puller T10055 Adapter T10055/2 Thrust plate T10184 Sealing grease G A1 Sheet metal screw approx. 4 mm diameter Removing Remove transfer case --> Transfer case, removing.

53 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 T Installing Fill area between sealing lip and dust lip halfway with sealing grease G A1. Fig. 63: Driving New Seal In As Far As Stop Drive new seal in as far as stop; be sure not to distort seal. Install transfer case --> Transfer case, installing. Check gear oil level in transfer case --> Gear oil level in transfer case, checking. Output flange oil seal for front driveshaft, replacing (transfer case installed)

54 Fig. 64: Identifying Special Tools - Output Flange Oil Seal For Front Driveshaft, Replacing (Transfer Case Installed) Special tools, testers and auxiliary items required Slide hammer VW 771 Pulling hook VW 771/37 Handle-Hold Dr. Shaft Flange 3145 Torque wrench V.A.G 1332 Thrust plate T10185 Socket T10204 Sealing grease G A1 Loctite 648

55 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 Fill area between sealing lip and dust lip halfway with sealing grease G A1. Fig. 66: Driving New Seal In As Far As Stop

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

57 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. Check gear oil level in transfer case --> Gear oil level in transfer case, checking. 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)

58 Fig. 70: Identifying Special Tools - Output Flange Oil Seal For Rear Driveshaft, Replacing (Transfer Case Installed) Special tools, testers and auxiliary items required Slide hammer VW 771 Pulling hook VW 771/37 Handle-Hold Dr. Shaft Flange 3145 Torque wrench V.A.G 1332 Thrust plate T10185 Socket T10204 Sealing grease G A1 Loctite 648

59 2 Bolts M10 x 25 Removing Remove rear driveshaft --> Rear driveshaft, removing and installing. 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 Pull out sealing ring using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37. Clean threads of nut.

60 Installing Fill area between sealing lip and dust lip halfway with sealing grease G A1. Fig. 73: Driving New Seal In As Far As Stop 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.

61 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). Install rear driveshaft --> Rear driveshaft, removing and installing. Check gear oil level in transfer case --> Gear oil level in transfer case, checking. 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 Special tools, testers and auxiliary items required

62 Fig. 77: Torque Wrench V.A.G 1331 Torque wrench V.A.G 1331 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 -.

63 Fig. 80: Removing Bolts And Differential Motor From Transfer Case 2006 Volkswagen Touareg 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 -.

64 " a = approx. 10 " 2006 Volkswagen Touareg 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 turned to "LOW" position with ignition on. Transfer Case Operating Unit E473 was not turned to "LOW" position. Transfer Case Operating Unit setting --> (Fig. 1) Transfer Case Operating Unit setting --> (Fig. 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 must be in - a - position.

65 If necessary, set the interrupted tooth pattern 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 must be in - a - position. " a = approx. 60 " If necessary, set the interrupted tooth pattern 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 of transfer case. Ensure that the interrupted teeth on differential motor - arrow A - and on selector shaft/transfer case - arrow B - are aligned.

66 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. Check gear oil level in transfer case --> Gear oil level in transfer case, checking. Tightening torque Differential motor to transfer case Bracket for transfer case 27 Nm 14 Nm

67 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.

68 Installation position: Colored spot on front driveshaft must line up with colored spot on front final drive 2006 Volkswagen Touareg 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

69 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

70 Always replace Front driveshaft, removing and installing Fig. 86: Identifying Special Tools - Front Driveshaft, Removing And Installing Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 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.

71 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 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 -.

72 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. Insert brake pedal depressor V.A.G 1869/2. Raise vehicle. Remove remaining three bolts from front driveshaft at front final drive and at transfer case.

73 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. Fig. 91: Unbolting/Tightening Transmission Carrier From/To Structure Unbolt transmission carrier - A - from structure - arrows -.

74 Fig. 92: Removing Bolts For Transmission Support From Transfer Case Console 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.

75 Fig. 94: Removing Bolts For Transmission Support From Transfer Case Console Install transmission carrier as follows: Use new bolts. First tighten the transmission carrier to the transfer case console - arrows - to tightening torque. Fig. 95: Unbolting/Tightening Transmission Carrier From/To Structure 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 Always replace bolts Transmission carrier to structure 50 Nm plus an additional 90 1 / 4 turn 50 Nm plus an additional 90 1 / 4 turn

76 Always replace bolts Front driveshaft to front final drive flange Always replace bolts Front driveshaft to transfer case flange 30 Nm plus an additional 90 1 / 4 turn 30 Nm plus an additional 90 1 / 4 turn Always replace bolts Rear driveshaft, removing and installing Fig. 96: Identifying Special Tools - Rear Driveshaft, Removing And Installing Special tools, testers and auxiliary items required

77 Torque wrench V.A.G 1332 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 rear driveshaft. 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 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. Insert brake pedal depressor V.A.G 1869/2. Raise vehicle. Remove rear part of exhaust system --> EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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 If an underbody impact guard is located beneath the driveshaft, remove it --> 50 - BODY - FRONT.

78 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 -.

79 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. Insert brake pedal depressor V.A.G 1869/2. 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.

80 Fig. 101: Removing/Installing Both Front Bolts On Subframe Support subframe with a wooden block --> Fig 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.

81 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 off of rear final drive 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 Installation is in reverse order of removal. Note the following:

82 Fig. 105: Identifying Mark On Driveshaft Flange & Rear Final Drive 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.

83 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 --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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. 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 Always replace bolts Rear driveshaft to flexible disc Always replace bolts Center bearing bracket to body 30 Nm plus an additional 90 1 / 4 turn 75 Nm 60 Nm Rear driveshaft center bearing, installing stress-free

84 If necessary, remove rear part of exhaust system --> EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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 Fig. 108: Loosening Bolts For Center Bearing Bracket & Unbolting Center Bearing Bracket From Body Remove bolts - arrows B -. Loosen bolts - arrows A - several turns. Fig. 109: Aligning Center Bearing Bracket Centrally To Lateral Stops On Body

85 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: Fig. 110: Unbolting/Tightening Transmission Carrier From/To Structure 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.

86 Fig. 111: Loosening Bolts For Center Bearing Bracket & Unbolting Center Bearing Bracket From Body Install bolts - arrows B - and fasten bolts - arrows A - and - arrows B -. If removed earlier, install rear part of exhaust system --> EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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 Torque specifications Center bearing bracket to body Rear driveshaft center bearing to bracket Transmission carrier to structure 60 Nm 20 Nm 50 Nm plus an additional 90 1 / 4 Always replace bolts Flexible disc, removing and installing Special tools, testers and auxiliary items required

87 Fig. 112: Torque Wrench V.A.G 1331 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Fig. 113: Brake Pedal Depressor V.A.G 1869/2 Brake pedal loading device V.A.G 1869/2 A twin-post vehicle hoist should be used when working on the rear driveshaft. 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. 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. Insert brake pedal depressor V.A.G 1869/2. Raise vehicle.

88 Remove rear part of exhaust system --> EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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. Fig. 114: Unbolting Flexible Disc From Rear Driveshaft Unbolt flexible disc from rear driveshaft - arrows -. Installing Install in reverse order, paying attention to the following:

89 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. Install rear driveshaft --> Rear driveshaft, removing and installing. 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 --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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. Tightening torque Flexible disc to transfer case flange 75 Nm Always replace nut, build torque at the bolt while counterholding the nut

90 39F FINAL DRIVE, FRONT DIFFERENTIAL GEAR OIL IN FRONT FINAL DRIVE, CHECKING Transmission oil specification --> Code letters, transmission allocation, gear ratios, capacities Special tools, testers and auxiliary items required Fig. 116: Torque Wrench V.A.G 1331 Torque wrench V.A.G 1331 Fig. 117: Removing Sealing Plug For Gear Oil Inspection Remove sealing plug for gear oil inspection - arrow -. 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

91 Remove bolt - arrow -. Top off oil to lower edge of filler hole. Fasten bolt - arrow - with new seal. 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 Special tools, testers and auxiliary items required

92 Tensioner hooks VW 552 Spindle A/11 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2 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 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.

93 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.

94 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 from left longitudinal member. When doing this, remove nut - A - and bracket - arrow B -. Fig. 124: Hooking Spindles A/11 In Eyelets Of Engine Carrier On Left/Right Vehicle Sides Hook spindles A/11 in eyes - arrow - of subframe on left and right sides of vehicle.

95 Fig. 125: Setting Wooden Block Into Hanger Of Each Spindle A/11 Set a wooden block - A - approx. 300 mm long into the hanger of each spindle 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 -.

96 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 Round Subframe cannot be secured. Mark position of subframe on body using a felt tip pen. Secure subframe before removal --> 40 - FRONT SUSPENSION Remove mounting bolts for subframe from body - arrows - in Fig Fig. 128: Removing/Installing Coupling Rods On Left/Right From Stabilizer Bar Disconnect left and right 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 A/11 by approx. 50 mm direction of - arrow - to remove bolt

97 Use bolts with additional washers, or bolts M14 x 1.5 approx. 90 mm long, to secure subframe to body on left and right 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 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.

98 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 through for front final drive - A - on subframe - B -. A second technician is required to remove front final drive.

99 Fig. 133: Removing Front Final Drive Rearward Between Subframe And Engine/Transmission Remove front final drive 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 Install in reverse order, paying attention to the following: Always replace bolts for front driveshaft. A second technician is required to insert front final drive into subframe supports.

100 Fig. 134: Removing/Installing Bolts With Nuts For Front Final Drive On Subframe Install bolts with nuts through 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.

101 Fig. 136: Hooking Spindles A/11 In Eyelets Of Engine Carrier On Left/Right Vehicle Sides Hook spindles A/11 in eyes - arrow - of subframe on left and right sides of vehicle. Fig. 137: Setting Wooden Block Into Hanger Of Each Spindle A/11 Set a wooden block approx. 300 mm long into hanger of each spindle 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.

102 Fig. 138: 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 Fig. 139: Removing/Installing Coupling Rods On Left/Right From Stabilizer Bar Remove temporarily installed bolts for subframe on left and right. Install bolts for air spring strut or suspension strut on lower control arm. Fasten coupling rods on left and right to stabilizer --> 40 - FRONT SUSPENSION.

103 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 Fig. 141: Placing Engine/Transmission Jack V.A.G 1383 A Under Engine Carrier If an axle alignment was performed, the bolts must be replaced --> 40 - FRONT SUSPENSION Tighten bolts to tightening torque --> 48 - STEERING. Remove spindles A/11 from subframe.

104 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 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.

105 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 runs from front final drive - 3 -, along behind right engine mount and then is clipped to the air filter

106 SEALS AT FRONT FINAL DRIVE, REPLACING Left flange shaft oil seal, replacing Fig. 146: Identifying Special Tools - Left Flange Shaft Oil Seal, Replacing Special tools, testers and auxiliary items required Punch VW 412 Thrust plate VW 432 Support channels VW 457 Slide hammer VW 771 Seal installer 2003/3

107 Alignment fixture 3301 Sealing grease G A1 Special tools, testers and auxiliary items required Fig. 147: Identifying Kukko Tools Kukko 17/2 Separating device Fig. 148: Thrust Plate T10260 Thrust plate T10260 Removing Remove front final drive --> Front final drive, removing.

108 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 /37 Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW /37. Installing

109 Fig. 151: Driving In New Oil Seal Up To Stop Drive in new oil seal up to stop. Fill area between sealing lip and dust lip halfway with sealing grease G A1. 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. Check gear oil in front final drive --> Gear oil in front final drive, checking. Dust cap for flange shaft, replacing

110 Fig. 153: Pressing Off Dust Cap From Flange Shaft Press off dust cap - B - from flange shaft. A - Separating device 22 to 115 mm, e.g. Kukko 17/2 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 Special tools, testers and auxiliary items required

111 Fig. 155: Slide Hammer-Multi-Purpose Tool Set VW 771 Slide hammer VW 771 Pulling hook VW 771/37 Fig. 156: Thrust Plate T10259 Thrust plate T10259 Sealing grease G A1 Removing Remove front final drive --> Front final drive, removing.

112 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. Fig. 158: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW /37 Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW /37. Installing

113 Fig. 159: Driving In New Oil Seal Up To Stop Drive in new oil seal up to stop. Fill area between sealing lip and dust lip halfway with sealing grease G A1. Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary. Fig. 160: 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. Check gear oil in front final drive --> Gear oil in front final drive, checking. Seal for driveshaft flange on front final drive, replacing (final drive removed)

114 Fig. 161: Identifying Special Tools - Seal For Driveshaft Flange On Front Final Drive, Replacing (Final Drive Removed) (1 Of 2) Special tools, testers and auxiliary items required Pressure plate VW 402 Punch VW 407 Punch VW 412 Slide hammer VW 771 Pulling hook 771/37 Sleeve 40-20

115 Fig. 162: Identifying Special Tools - Seal For Driveshaft Flange On Front Final Drive, Replacing (Final Drive Removed) (2 Of 2) Special tools, testers and auxiliary items required Counter holder 3435 Torque wrench V.A.G 1576 Friction meter VAS 6222 Thrust plate T Kukko 17/2 Separating device Sealing grease G A1 Loctite Bolts M10 x 25

116 Removing Remove front final drive --> Front final drive, 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 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).

117 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

118 Fig. 167: Driving New Seal In As Far As Stop Drive new seal in as far as stop; be sure not to distort seal. Fill area between sealing lip and dust lip halfway with sealing grease G A1. Before installing driveshaft flange, check dust cap for damage. Replace dust cap if necessary. Install driveshaft flange, being aware of marking from removal. Coat threads of new nut with locking fluid Loctite 648. 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)

119 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! Install front final drive --> Front final drive, installing. Check gear oil in front final drive --> Gear oil in front final drive, checking. Dust cap for driveshaft flange, replacing Fig. 170: Pressing Dust Cap Off Of Driveshaft Flange Press dust cap off of driveshaft flange. A - Separating device 22 to 115 mm, e.g. Kukko 17/2

120 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 NEEDLE BEARING FOR LEFT FLANGE SHAFT, REPLACING Needle bearing for left flange shaft, replacing

121 Fig. 172: Identifying Special Tools - Needle Bearing For Left Flange Shaft, Replacing Special tools, testers and auxiliary items required Mandrel Thrust pad B Kukko 21/6 Internal puller Kukko 22/2 Counter-support Needle bearing, removing Remove front final drive --> Front final drive, removing. Remove left flange shaft and seal --> Left flange shaft oil seal, replacing.

122 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. Install front final drive --> Front final drive, installing. Check gear oil in front final drive --> Gear oil in front final drive, checking. BONDED RUBBER BUSHING AT FRONT FINAL DRIVE, REPLACING Bonded rubber bushing at front final drive, replacing

123 Fig. 175: Identifying Special Tools - Bonded Rubber Bushing At Front Final Drive, Replacing (1 Of 2) Special tools, testers and auxiliary items required Thrust plate VW 442 Sleeve Alignment fixture 3301 Alignment fixture 3346 Alignment fixture 3347

124 Fig. 176: Identifying Special Tools - Bonded Rubber Bushing At Front Final Drive, Replacing (2 Of 2) Special tools, testers and auxiliary items required Thrust pad VW 512 Thrust plate VW 554 Alignment fixture 3253 Alignment fixture T10030 Bonded rubber bushing, installation position Bonded rubber bushings with 2 recesses

125 Fig. 177: Bonded Rubber Bushings With 2 Recesses The recesses in the bushing must be vertical relative to final drive - arrows -. Bonded rubber bushings with 4 recesses Fig. 178: Bonded Rubber Bushings With 4 Recesses 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

126 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.

127 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 Fig. 182: Pulling Out Bonded Rubber Bushing Pull out bonded rubber bushing. It is important to grease spindle 3346/2 with Molybdenum grease before using. To pull out, place special tool 3346/1 with flat shoulder facing toward bonded rubber bushing onto spindle 3346/2.

128 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

129 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

130 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

131 Fig. 186: Location Of Transfer Case Operating Unit E473 The transfer case operating unit E is located in the shift cover 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)

132 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

133 Separate connector at differential lock control module J647. Remove bolt Unclip holder with differential lock control module J from structure - arrows - and remove holder with differential lock control module J647. Installing Installation is in reverse order of removal. Note the following: Fig. 190: Identifying Differential Lock Control Module J647 Connector, Bolt & Differential Lock Control Module J647 Clip holder with differential lock control module J into structure - arrows -. Tighten bolt 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 Transmission oil specification --> Code letters, transmission allocation, gear ratios, capacities Special tools, testers and auxiliary items required

134 Fig. 191: Torque Wrench V.A.G 1331 Torque wrench V.A.G 1331 Fig. 192: Removing Sealing Plug For Gear Oil Inspection Remove sealing plug for gear oil inspection - arrow -. The oil level is correct when the rear final drive is filled to the lower edge of the filler hole. Fasten bolt - arrow - with new seal. When initially filling rear final drive Remove bolt - arrow -. Top off oil to lower edge of filler hole. Fasten bolt - arrow - with new seal. Tightening torque Oil filler plug to rear final drive 35 Nm

135 REAR FINAL DRIVE, REMOVING AND INSTALLING Rear final drive, removing and installing Fig. 193: Identifying Special Tools - Rear Final Drive, Removing And Installing Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2 Rear final drive, removing Raise vehicle.

136 If an underbody impact guard is located beneath the rear final drive, remove it --> 50 - BODY - FRONT. Remove rear part of exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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. Fig. 194: Identifying Mark On Driveshaft Flange & Rear Final Drive 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 -.

137 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 and right 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 -.

138 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 Installation is in reverse order of removal. Note the following: Always replace bolts for rear driveshaft. Fig. 198: Identifying Mark On Driveshaft Flange & Rear Final Drive 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.

139 Fig. 199: Fastening Rear Final Drive To Subframe Fasten rear final drive to subframe - arrows - --> 42 - REAR SUSPENSION. Fasten right and left 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. Install rear part of exhaust system --> EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, 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 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE 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 Breather line for rear final drive, routing

140 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 Special tools, testers and auxiliary items required Fig. 201: Torque Wrench V.A.G 1331 Torque wrench V.A.G 1331 Differential lock motor V304, removing Separate two connectors at differential lock motor.

141 Fig. 202: Setting Differential Lock Motor V304 With Holder For Connector Into Rear Final Drive 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

142 installed. O-ring is secured with a protective sleeve. Remove protective sleeve before installing Differential lock motor V304. Fig. 204: Setting Differential Lock Motor V304 With Holder For Connector Into Rear Final Drive 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)

143 Fig. 205: Identifying Special Tools - Seal For Left Flange Shaft, Replacing (Vehicles Without Differential Lock) Special tools, testers and auxiliary items required Pressure plate VW 402 Punch VW 412 Slide hammer VW 771 Pulling hook VW 771/37 Tube Kukko 17/2 Separating device Sealing grease G A1

144 Special tools, testers and auxiliary items required Fig. 206: Thrust Plate T10256 Thrust plate T10256 Removing Remove rear final drive --> Rear final drive, removing. Fig. 207: Securing Slide Hammer VW 771 To Left Flange Shaft Secure slide hammer VW 771 to left flange shaft. Pull out left flange shaft.

145 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 Fig. 209: Driving In New Oil Seal Up To Stop Drive in new oil seal up to stop. Fill area between sealing lip and dust lip halfway with sealing grease G A1. Before installing the flange shaft, check the dust cap for damage. Replace dust cap if necessary.

146 Fig. 210: 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 rear final drive --> Rear final drive, installing. Checking gear oil in rear final drive --> Gear oil in rear final drive, checking. Dust cap for flange shaft, replacing Fig. 211: Pressing Off Dust Cap From Flange Shaft Press off dust cap - B - from flange shaft. A - Separating device 22 to 115 mm, e.g. Kukko 17/2

147 Fig. 212: Pressing Dust Cap Onto Flange Shaft Press dust cap - A - onto flange shaft. Seal for left flange shaft, replacing (vehicles with differential lock)

148 Fig. 213: Identifying Special Tools - Seal For Left Flange Shaft, Replacing (Vehicles With Differential Lock) Special tools, testers and auxiliary items required Pressure plate VW 401 Pressure plate VW 402 Punch VW 407 Punch VW 412 Slide hammer VW 771 Pulling hook VW 771/37 Sleeve 3144 Sealing grease G A1

149 Special tools, testers and auxiliary items required Fig. 214: Identifying Kukko Tools Kukko 17/2 Separating device Fig. 215: Thrust Plate T10258 Thrust plate T10258 Removing Remove rear final drive --> Rear final drive, removing.

150 Fig. 216: Securing Slide Hammer VW 771 To Left Flange Shaft Secure slide hammer VW 771 to left flange shaft. Pull out left flange shaft. Fig. 217: Pulling Out Seal For Flange Shaft Using VW 771/1 And VW 771/37 Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37. Installing

151 Fig. 218: Driving In New Oil Seal Up To Stop Drive in new oil seal up to stop. Fill area between sealing lip and dust lip halfway with sealing grease G A1. Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary. Fig. 219: 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 rear final drive --> Rear final drive, installing. Checking gear oil in rear final drive --> Gear oil in rear final drive, checking. Dust cap for flange shaft, replacing

152 Fig. 220: Pressing Off Dust Cap From Flange Shaft Press off dust cap - B - from flange shaft. A - Separating device 22 to 115 mm, e.g. Kukko 17/2 Fig. 221: Pressing Dust Cap Onto Flange Shaft Press dust cap - A - onto flange shaft. Seal for right flange shaft, replacing (vehicles without differential lock) Special tools, testers and auxiliary items required

153 Fig. 222: Slide Hammer-Multi-Purpose Tool Set VW 771 Slide hammer VW 771 Pulling hook VW 771/37 Fig. 223: Thrust Plate T10181 Thrust plate T10181 Sealing grease G A1 Removing Remove rear final drive --> Rear final drive, removing.

154 Fig. 224: Securing Slide Hammer VW 771 To Right Flange Shaft Secure slide hammer VW 771 to right flange shaft. Pull out right drive flange. Fig. 225: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37. Installing

155 Fig. 226: Driving In New Oil Seal Up To Stop Drive in new oil seal up to stop. Fill area between sealing lip and dust lip halfway with sealing grease G A1. Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary. Fig. 227: 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 rear final drive --> Rear final drive, installing. Check gear oil in rear final drive --> Gear oil in rear final drive, checking. Seal for right flange shaft, replacing (vehicles with differential lock)

156 Fig. 228: Slide Hammer-Multi-Purpose Tool Set VW 771 Slide hammer VW 771 Pulling hook VW 771/37 Fig. 229: Thrust Plate T10257 Thrust plate T10257 Sealing grease G A1 Removing Remove rear final drive --> Rear final drive, removing.

157 Fig. 230: Securing Slide Hammer VW 771 To Right Flange Shaft Secure slide hammer VW 771 to right flange shaft. Pull out right drive flange. Fig. 231: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37. Installing

158 Fig. 232: Driving In New Oil Seal Up To Stop Drive in new oil seal up to stop. Fill area between sealing lip and dust lip halfway with sealing grease G A1. Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary. Fig. 233: 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 rear final drive --> Rear final drive, installing. Check gear oil in rear final drive --> Gear oil in rear final drive, checking. Sealing ring for driveshaft flange on rear final drive, replacing (final drive removed)

159 Fig. 234: Identifying Special Tools - Sealing Ring For Driveshaft Flange On Rear Final Drive, Replacing (Final Drive Removed) (1 Of 2) Special tools, testers and auxiliary items required Pressure plate VW 402 Punch VW 407 Punch VW 412 Slide hammer VW 771 Pulling hook VW 771/37 Sleeve 40-20

160 Fig. 235: Identifying Special Tools - Sealing Ring For Driveshaft Flange On Rear Final Drive, Replacing (Final Drive Removed) (2 Of 2) Special tools, testers and auxiliary items required Handle-Hold Dr. Shaft Flange 3145 (change: expand holes to 10 mm diameter) Torque wrench V.A.G 1576 Friction meter VAS 6222 Thrust plate T Kukko 17/2 Separating device Sealing grease G A1 Loctite Bolts M10 x 25

161 Removing If necessary, expand holes in Counterhold 3145 to 10 mm diameter. Remove rear final drive --> Rear final drive, removing. 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 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).

162 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. Pull out sealing ring using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37. Clean threads for nut on drive pinion. Installing Fig. 239: Driving New Seal In As Far As Stop Drive new seal in as far as the stop; be sure not to distort seal. Fill area between sealing lip and dust lip halfway with sealing grease G A1. Before installing driveshaft flange, check dust cap for damage. Replace dust cap if necessary. Install driveshaft flange, being aware of marking from removal. Coat threads of new nut with locking fluid Loctite 648.

163 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! Install rear final drive --> Rear final drive, installing. Checking gear oil in rear final drive --> Gear oil in rear final drive, checking. Dust cap for driveshaft flange, replacing

164 Fig. 242: Pressing Dust Cap Off Of Driveshaft Flange Press dust cap off of driveshaft flange. A - Separating device 22 to 115 mm, e.g. Kukko 17/2 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 BONDED RUBBER BUSHING ON REAR FINAL DRIVE, REPLACING Bonded rubber bushing on rear final drive, replacing

165 Fig. 244: Identifying Special Tools - Bonded Rubber Bushing On Rear Final Drive, Replacing Special tools, testers and auxiliary items required Thrust plate VW 442 Thrust plate VW 554 Sleeve Alignment fixture 3301 Alignment fixture 3346 Alignment fixture 3347 Bonded rubber bushing, installation position

166 Bonded rubber bushings with 2 recesses Fig. 245: Bonded Rubber Bushing, Installation Position The recesses in the bushing must be vertical relative to final drive - arrows -. Bonded rubber bushings with 4 recesses Fig. 246: Bonded Rubber Bushings With 4 Recesses 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

167 Fig. 247: 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 - 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).