Removing and Installing Transfer Gear
Removing and installing transfer gear
Preliminary work for transfer gear
1. Remove engine guard.
2. Remove rear cardan shaft.
Removing transfer gear
Overview of removing and installing transfer gear
Information
^ To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating the foot brake.
1. Remove front cardan shaft on the transfer gear and tie it up.
Front cardan shaft to transfer gear
Information
^ The temperature sensor -1- on the transfer box is no longer used in model year 2004.
^ If there is no temperature sensor, secure cable plug on the servo motor with tie-wraps.
Plug sequence for transfer box servo motor
2. Pull off cable plug on the servo motor -1, 2- and release cable holder.
Cable plug on servo motor
Information
Always observe the exact work sequence when installing/removing the transmission cross member.
3. Remove transmission cross member.
4. Support transmission with transmission jack and secure with retaining band.
5. Unscrew bolts on body -A-.
Transmission cross member
6. Unscrew two transmission cross member screws -B- on transfer gear holder.
7. Place a wooden block -arrow- between the converter bell housing and suspension subframe.
Supporting transmission
8. Unscrew fastening nut and push holder with Tiptronic line -A- away to the side.
Tiptronic line holder
9. Unscrew fastening screws -arrows- securing transfer gear to main transmission.
Transfer gear to main transmission
10. Separate transfer gear from main transmission.
Removing transfer gear
11. Gradually drain transfer gear. Pull out vent line -arrows- and remove it from the retainers on the upper side.
Vent line holder
Installing transfer gear
1. Support main transmission on converter bell housing with a wooden block -arrow-.
Supporting transmission
2. Gradually run in transfer gear. Press vent line into holder -arrow- and attach to transfer gear.
Vent line holder
3. Screw in fastening screws on main transmission. -> Tightening torque: 45 Nm (33 ftlb.)
Transfer gear to main transmission
4. Tighten holder -A- for Tiptronic line using fastening nut -arrow-. -> Tightening torque: 10 Nm (7.5 ftlb.)
Transfer gear
5. Support transfer gear with transmission jack and remove wooden block between converter bell housing and suspension subframe.
Supporting transmission
Information
Always observe the exact work sequence when installing/removing the transmission cross member.
Information
^ Screws which are tightened with a torque angle must be replaced with new ones.
6. Install transmission cross member.
7. Screw in two cross member screws -B- on transfer gear holder. -> Initial tightening: 50 Nm (37 ftlb.) -> Final tightening: 90°
Transmission cross member
8. Screw in fastening screws for securing transmission cross member to body -A-. -> Initial tightening: 50 Nm (37 ftlb.) -> Final tightening: 90°
Information
^ Screws which are tightened with a torque angle must be replaced with new ones.
9. Connect front cardan shaft to transfer gear. -> Initial tightening: 30 Nm (22 ftlb.) -> Final tightening: 90°
Front cardan shaft to transfer gear
Information
^ The temperature sensor -1- on the transfer box is no longer used in model year 2004.
^ If there is no temperature sensor, secure cable plug on the servo motor with tie-wraps.
Plug sequence for transfer box servo motor
10. Connect cable plug -1, 2- to the transfer gear and secure the cable holder.
Cable plug on servo motor
Subsequent work for transfer gear
Reworking transfer box
1. Install cardan shaft.
2. Fit engine guard.