Center Differential, Transmission Installed

Center Differential, Transmission Installed

Special tools, testers and auxiliary items required

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/5)

• Gearbox Support (T10337)

• Oil Collecting and Extracting Device (V.A.G 1782)

• Torque Wrench 5-50 Nm (V.A.G 1331)

Removing

- Loosen the quick-release fasteners - 2 and 3 - and remove the rear noise insulation.






- Place the (V.A.G 1782) under the transmission.

- Remove the plug - arrow - and drain the transmission fluid.






- Install the plug - arrow - and tighten it to 45 Nm.

Vehicles with a Single Pipe Exhaust System







The decoupling element in the front exhaust pipe could be damaged.

• Do not bend the decoupling elements in the front exhaust pipe more than 10°.

- Loosen the bolts - arrows -, slide the sleeve to the rear and tie up the front exhaust pipe to the body.

Vehicles with Dual Pipe Exhaust System







Danger of damaging the flex joint in the front muffler.

• Do not bend the decoupling element in the front muffler more than 10°.

- Loosen the clamping sleeve - 1 and 2 -, slide it to the rear and tie it up to the body.

- Remove the bolts - arrows - and remove the driveshaft heat shield - A - (if equipped) for the driveshaft.






Driveshaft Bolted on the Transmission Side






- Remove the bolts that connect the driveshaft to the transmission by counter holding them with the (T10172) and (T10172/5).

- Press the driveshaft together with rear final drive; the universal joint is able to slide axially.

- Secure the driveshaft to the side.

Driveshaft Connected on the Transmission Side

- Remove the driveshaft.

All Vehicles






- Support the transmission using the (V.A.G 1383 A) with the (T10337) attached.


There is the risk of an accident.

• The (V.A.G 1383 A) may only be used during assembly and must not sit unsupervised under the vehicle.

- Remove the bolts from the tunnel crossmember - arrows -.






- Lower the transmission to dimension - a - using the (V.A.G 1383 A).






• Dimension - a - = maximum 80 mm (3.14 inches).

- Remove the nuts - arrow - and the tunnel crossmember.






- Place the (V.A.G 1782) under the transmission.






- Remove the bolts - A, B and arrows -.

• Not all versions have the double bolts - B -.


Danger of damaging the center differential.

• Carefully and slowly pull the center differential housing off of transmission toward rear. Otherwise the center differential can fall out of the transmission.

• A center differential that has fallen out may not be installed. This must be replaced.

- Carefully remove the center differential housing - 6 -, the pressure spring - 3 -, the adjusting shim - 4 - and the plate spring - 5 -.






- Remove the center differential - 2 - and the gear carrier - 1 -.

If the gear carrier - 1 - remains in the center differential housing, proceed as follows:






- Hold the gear carrier - 1 - by one of the side ribs with pliers and remove it in direction of - arrow A -.

- At the same time, carefully hit housing - arrow B - alternating from one side to the other using a rubber hammer.


Do not damage sealing surfaces when doing this.

Center Differential Housing, Installing






• Tightening specifications, refer to => [ Center Differential and Center Differential Housing Overview ] Center Differential and Center Differential Housing Overview

- Clean both joint surfaces in the housing.

Install the gear carrier on the transmission as follows:

• Installed position: The tab - arrow A - on the gear carrier - 2 - must installed into the opening - arrow B - inside the transmission cover.

• The oil catch tray - 1 -, the spacer sleeve - 3 - and the adjusting shim - 4 - are installed.

- Slide the center differential - 2 - all the way in direction of the gear carrier - 1 -.






- Install the plate spring - 5 -, the adjusting shim(s) - 4 - and the pressure spring - 3 - in the center differential housing - 6 -.

• Plate spring installed location - 5 -: The camber on the inner diameter - arrow - faces toward the center differential housing - 6 -.

- Apply sealing compound (AMV 188 001 02) evenly and not too thickly.

- Then position the center differential housing - 6 - on the transmission.

- Press the center differential housing - C - on until it makes contact with the transmission cover and hold it securely.






- Install the new bolts - A, B and arrows - and tighten them. Tightening specification, refer to => [ Center Differential and Center Differential Housing Overview ] Center Differential and Center Differential Housing Overview.

• Not all versions have the double bolts - B -; allocation, refer to the Parts Catalog. Aluminum bolts are installed in place of the double bolts.

- Install the tunnel crossmember and tighten it. Refer to => [ Tunnel Crossmember, Transmission Mount and Transmission Support Overview ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.






- Secure the driveshaft on the transmission.






- Install the driveshaft heat shield - A - and tighten the bolts - arrows - to 25 Nm, if equipped.






- Fill transmission oil and check oil level. Refer to => [ Transmission Fluid Level, Checking ] Service and Repair.

- Install the exhaust system and align it without tension.

- Install the noise insulation.