Transfer Case, Disassembly and Assembly
Transfer Case
Special tools, testers and auxiliary items required
• Holding plate (VW 309)
• Transmission support (VW 353)
• Pressure plate (VW 401)
• Pressure plate (VW 402)
• Punch (VW 412)
• Thrust piece (VW 434)
• Thrust piece (VW 473)
• Thrust piece (30 - 11)
• Tube (2040)
• Thrust piece (3002)
• Thrust pad (3062)
• Retainer (3145)
• Tube for wheel bearing (3345)
• Torque Wrench (V.A.G 1601)
• Engine and Transmission Holder (VAS 6095)
• - 1 - Two arm puller (Kukko 20/10)
• Sealing grease (G 052 128 A1)
• Sealant (AMV 174 004 01)
• 2 bolts M10 x 25 mm
Disassembling transfer case
- Clamp transfer case in the holding fixture - arrows -.
- Remove damper - 1 - from the transfer case (near the input flange/rear driveshaft) - arrows - if applicable.
- Remove damper and bracket from the transfer case (near the oil drain plug), where applicable. Refer to => [ Damper and Bracket, Removing from Transfer Case and Installing ] Damper and Bracket, Removing From Transfer Case and Installing.
- Place drip tray under the transfer case.
- Remove oil drain plug - 3 - with ratchet 3/8" and drain transmission oil.
- Remove cap - 2 -.
- Remove rear output flange/driveshaft nut.
A Hex bolts M10 x 25
B Socket SW 30
- Remove output flange.
• If it is difficult to move, remove the output flange using a puller - A -, for example (Kukko 20/10).
- Remove the cover/transfer case to housing/transfer case bolts.
- Carefully pry off cover/transfer case all around while alternating sides on protruding flange, do not damage sealing surfaces.
- Remove input shaft - A - from the chain sprocket in direction of - arrow -.
- Remove and clean magnet - B -.
- Remove chain sprocket - 1 - and remove chain - 2 - from chain sprocket - 4 -.
• The chain has a specific installation direction. The marked chain links - 3 - must face the transfer case cover.
- Remove self-locking center differential - A -.
- Remove chain sprocket from the flange shaft - B -. While doing this, secure the flange shaft from falling down.
A Two arm puller, e.g. (Kukko 20/10)
- Remove chain sprocket and spacer sleeve => [ (Item 4) Spacer sleeve ] Output Shaft, Chain, Chain Sprockets and Self-Locking Center Differential Assembly Overview.
- Carefully unclip and remove oil collector tray - A - from the catches - B - in the housing.
- Remove input shaft circlip - 1 - - 2 -.
- Remove input shaft and the ball bearing from the housing/transfer case.
• Some transmissions may have the ball bearing push fit (not press fit) in the housing. The input shaft and the ball bearing can be removed by hand.
Assembling transfer case
• If the transfer case seals do not have to be replaced, then fill the space between the sealing lips - arrow - halfway with sealing grease (G 052 128 A1).
- Install the input shaft and ball bearing into the housing/transfer case. When doing this, carefully guide the input shaft through the input shaft seal.
- Install the input shaft all the way into the housing/transfer case.
- Install the circlip - 1 - for the input shaft/ball bearing - 2 - into the groove in the housing.
- Install oil collector tray - A - into the ridge on the housing flanges - B -. Turn the oil collector tray so that the tab - arrow 1 - contact the housing rib - arrow 2 -.
- Mount housing/transfer case with the installed flange shaft - A - to the thrust piece (VW 473).
- Guide spacer sleeve - B - over the flange shaft.
- Install chain sprocket - C - with the shoulder - arrow - facing the press tube (2040).
- Install chain sprocket all the way.
• On some transfer cases, the flange shaft may have a loose-fit connection (not press-fit) to the chain sprocket. The flange shaft must be secured from falling down!
- Install self-locking center differential - A - into the input shaft splines.
• Always pay close attention to the installation direction when installing the chain - 2 -. The chain must be installed so that the marked chain links - 3 - face the transfer case cover.
- First install chain - 2 - into the teeth on the sprocket - 4 -.
- Then install the sprocket - 1 - into the chain - 2 -.
- Then install chain sprocket - 1 - all the way into the center differential splines.
- Install output shaft - A - all the way into the chain sprocket splines and center differential in direction of - arrow -.
- Install cleaned magnet - B -.
- Make sure alignment sleeves - C - are installed in the housing/transfer case.
- Apply sealant (AMV 174 004 01) evenly onto the sealing surface of the housing.
- Install cover/transfer case.
- Tighten cover/transfer case bolts to the tightening specification diagonally starting from the inside and working out.
- Install flange shaft circlip - 1 - - 2 -.
- Install output flange for rear driveshaft; use a plastic hammer if necessary.
- Coat washer - arrow - with transmission oil and install it.
- Place washer => [ (Item 11) Washer ] Transfer Case Cover Assembly Overview on the seal.
- Tighten new nuts for the output flange/rear driveshaft to the tightening specification => [ (Item 12) Nut ] Transfer Case Cover Assembly Overview.
A Hex bolts M10 x 25
B Socket SW 30
- Install damper - 1 - to the transfer case (near the input flange/rear driveshaft) - arrows - if applicable. Refer to => [ Transfer Case Damper near Rear Output Flange and Rear Driveshaft ] Transfer Case Damper Near Rear Output Flange and Rear Driveshaft.
- Install cover - 2 - and O-ring and tighten to the tightening specification => [ (Item 2) Sealing cap ] Transfer Case Cover Assembly Overview.
- Tighten oil drain plug - 3 - with a socket wrench and a 3/8" extension to tightening specification => [ (Item 4) Oil drain plug ] Transfer Case Cover Assembly Overview.
- If equipped, attach the bracket and balance weight (near the oil drain plug) to the transfer case. Refer to => [ Damper and Bracket, Removing from Transfer Case and Installing ] Damper and Bracket, Removing From Transfer Case and Installing.
- Remove transfer case from the holding fixture.
• After installing the transfer case, fill with transmission oil and check the level. Refer to => [ Checking Gear Oil Level in Transfer Case ] Service and Repair.