Bevel Gear Transfer Case, Removing and Installing
Bevel Gear Transfer Case, Removing and Installing
Special tools and equipment
- 3287A ball joint puller
- V.A.G 1669 hex extension or 6 mm hex socket at least 190 mm long (locally available)
- V.A.G 1332 torque wrench
- Catch basin
Removing
Vehicles with 1 charge air cooler:
- Remove air guide duct to charge air cooler at long member at lower right.
All models
- Remove noise insulation in the center and on right side - arrows -.
- Remove crossmember-3- from aggregate carrier - 1 -.
- If fitted, unbolt exhaust mounting from subframe.
- Disconnect exhaust system at clamp - arrows -.
- Push clamp toward rear of vehicle.
- Mark alignment of driveshaft with flexible disk to flange of angular gear.
- Remove driveshaft with flexible disk from flange of angular gear (arrow).
Notes: Counterhold triangle flange using a lever to remove bolts.
- Press front pipe of driveshaft as far rearward as possible.
Notes: The engine/transmission assembly will move forward slightly when the bolts - A - are slackened (Fig. N34-0887, below). Take care not to damage the seal -arrow- in the driveshaft flange when removing and installing.
- Unbolt pendulum support from subframe (arrows A).
- Press engine/transmission forward carefully.
- Unscrew nut on connecting link from anti - roll bar (right side).
- Remove upper nut on suspension ball joint (right side).
- Apply ball joint splitter as shown in illustration and press out ball joint.
Notes: To protect the thread, leave the nut screwed a few turns on the ball joint thread.
- Turn the steering wheel to the left.
- Remove heat shield for right drive axle from bevel box.
- Unbolt right drive axle at transmission, move clear and tie up
- Place container under the transmission.
- Drain off gear oil - arrow 2.
- Remove right drive flange bolt - arrow 1 - using V.A.G 1669.
- Unscrew bolts -1- and -2- on bracket for bevel box.
Notes: The bracket cannot be removed at this stage and must be left in position.
- Remove bevel box/transmission securing bolts.
- Press bevel box off transmission.
- Take out bevel box.
Installing
Installation is carried out in the reverse sequence, when doing this note the following:
- Always replace the O-ring between the bevel box and the transmission (arrow - A -) and the seals for the oil - feed passages (arrows - B - and - C -).
- Lightly lubricate the O-ring and the seals with oil before installing.
- Push the bevel box all the way up against the transmission. When doing this, guide the splines on the bevel box input shaft centrally into the connecting sleeve on the differential.
- If the splines are positioned correctly and located centrally, the bevel box will slide all the way up against the transmission housing.
Notes: Do not pull the bevel box onto the transmission with the securing bolts, as otherwise the bevel box will be not be fitted squarely and the securing lugs could break off.
- Put the bracket for the bevel box in place before screwing in the bolts securing the bevel box to the transmission.
- Tighten bolts securing bevel box to transmission (45 Nm + - 1/4 turn = 90°).
- Use new bolts for securing.
- Screw in bolts - arrow 1 - and - arrow 2- loosely.
- Secure bracket for bevel box. When doing this, keep to the following sequence: - Initially tighten bolts - arrow 1 - to 3 Nm.
- Tighten bolts - arrow 2 - to 35 Nm.
- Tighten bolts - arrow 1 - to 45 Nm.
- Tighten right drive flange bolt - arrow 1 - using V.A.G 1669 (25 Nm).
- Bolt drive axles to transmission (M10 bolts: 77 Nm)
- Install right drive axle guard (25 Nm).
- Press engine/transmission assembly toward bulkhead; the guide pin on the bevel box must be guided carefully into the driveshaft flange when doing this.
Notes:
^ Take care not to damage the seals in me driveshaft flanges when removing and installing. The driveshaft must be replaced if the seals are damaged.
^ Ensure driveshaft is horizontal when pushing onto guide pin.
- Bolt pendulum support onto subframe - arrows A -. (20 Nm + 1 /4 turn = 90°).
- Use new bolts for securing.
- Unbolt cross member-3- from aggregate carrier- 1 -.
- Mark position of drive shaft with flexible disc to flange of angled final drive.
- Unbolt drive shaft with flexible disc from flange of angled final drive (arrows).
Notes: To remove bolts, counter - hold at triangular flange using lever.
- If installed, install diagonal brace -1- with new bolts -4- and locking compound D 000 600 A2. Installation position: Mount imprint "L" or "left" on left side in direction of travel. The foam strip (arrow) points downward. Tightening torque: 30 Nm 90� Fill transmission oil in manual transmission with angled final drive.
- Bolt driveshaft onto flexible coupling on bevel box - arrows - (60 Nm).
- Reconnect exhaust system.
- Install suspension ball joint and connecting link: