Removal and Replacement

Transfer Case

Special tools, testers and auxiliary items required

• Transmission Support (3282)

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/6)

• Engine Support Basic Set (T40091)

• Adapter (T40093/6) off engine Support Supplement Set (T40093)

• Grease for clutch disc shaft splines (G 000 100)

Removing

- Activate the vehicle lift mode in vehicles with air suspension.

- Remove the rear driveshaft; refer to => [ Rear Driveshaft ] Rear Driveshaft.

- Remove the bolts and the rear noise insulation - 2 -.






- Separate the electrical connectors - 1, 2, 3 - on the transmission.






Vehicles Equipped with a 3.0L TFSI Engine:

- Remove the bolts - 1, 2, 3 -.






- Remove the bracket - 4 -.

Vehicles Equipped with a 3.0L TDI Engine:

- Remove the bolts - arrows - on the bracket for the particulate filter.






All Vehicles

- Remove the bolts - arrows - from the connection between the front driveshaft and the transfer case.






- Use a (T10172) to counter hold the (T10172/6).

- Secure the front driveshaft to the body so it is up and out of the way.

- Slide the adapter (T40093/6) onto the crossmember (T40091/1)






- Then slide the (T40091/1) into the adapters (T40091/4) and (T40091/5) and secure with the bolts - arrows -.

- Use the bolts to tighten the adapter - A - to the body.

• Tighten the (T40091/5) on the left side to 30 Nm using the M10x30 bolt.

• Use the M8x30 mm bolt and washer to tighten the (T40091/4) on the right side to 23 Nm.

- Secure the transmission support to the transfer case using bolt M8 x 20 - A arrow - and the M10 x 20 bolt - B arrow -.






- Secure the bolts (3282/45) on the transmission support on the right side using an M8 nut.

- Attach the bolt (3282/45) on the transmission support on the left side using a washer - 1 -.

- Remove bolts - 1, 2 - for the transmission support.






- Use the (V.A.G 1383 A) to lower the transmission case by dimension - a - between the body and the transmission support - 1 -.






• Dimension - a - = approximately 50 mm

- Install the spindle (T40091/6) with the square nut (T40091/7) into the adapter (T40093/6).






- Position the spindle (T40091/6) and the pressure piece (T40091/8) on the automatic transmission housing.

- Lock the nut - A - to prevent the spindle (T40091/6) from turning.

- Remove the bolts that connect the transmission to the transfer case - 1 arrows - and - 2 arrows -.






- Pull the transfer case off of the transmission.

- Remove the transmission support - arrows - and the bracket bolts - 1, 2 - from the transfer case when replacing the transfer case; refer to => [ Transmission Support and Bracket Overview ] Transmission Support and Bracket Overview.






Installing

Install in reverse order of removal. Note the following:

• Tightening specifications, refer to => [ Transfer Case Overview ] Transfer Case Overview.

- Pay special attention to the proper seating for the alignment sleeves that are located between the transfer case and the transmission.

- Grease the driveshaft splines on the transfer case and the driveshaft splines on the transmission using grease for clutch disc shaft splines (G 000 100).

- Make sure that none of the wires get pinched between the transfer case and transmission when pushing them together.

- Align the bolting flange for the transfer case parallel with the flange/transmission. While doing this, use the spindles on the (3282) to adjust the transfer case.






- Push the transfer case all the way on to the transfer case by centrically joining the driveshaft splines/transfer case with output shaft.

• If required, turn the rear output flange/driveshaft back and forth a few times.

• When the gear positioning and centric guide are properly positioned, the transfer case will slide up to the stop up against the transmission.

• Do not pull the transfer case and bolts against the transmission, since otherwise the transfer case will tilt.

- Tighten the bolts - arrows 1 - and - arrows 2 - to tightening specification.






- Use the (V.A.G 1383 A) to lift the transfer case.

- Tighten the new transfer support bolts - 1, 2 -; refer to => [ Transmission Support and Bracket Overview ] Transmission Support and Bracket Overview.






- Use new bolts to bolt the rear driveshaft to the transfer case. Refer to => [ Rear Driveshaft ] Rear Driveshaft.

- Use new bolts to bolt the front driveshaft to the transfer case. Refer to => [ Front Driveshaft ] Front Driveshaft.

- Install the exhaust system so that there is no tension placed on it.

- Install the rear noise insulation.

- Deactivate the vehicle lift mode using a vehicle with air suspension.