Transfer Case: Service and Repair
WM 396519 Removing and installing transfer gear
Tools
Preliminary work for transfer gear
1. Remove sound insulation under transmission and holders. -> 108019 Removing and installing engine guard 108019 Removing and installing engine guard
2. Remove exhaust system. -> 260119 Removing and installing exhaust system Service and Repair
3. Remove rear cardan shaft. -> 393519 Removing and installing rear cardan shaft 393519 Removing and installing rear cardan shaft
4. Remove front cardan shaft. -> 390219 Removing and installing front cardan shaft 390219 Removing and Installing Front Cardan Shaft
Removing transfer gear
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
1. Screw both exhaust system holders off the transfer gear -arrows-.
Removing exhaust system holders
On vehicles with an electronically controlled multiplate clutch, the electric plug connections must also be disconnected.
2. Release the connectors -1- and -2 - ( -a, b- ) and pull them off.
Plug connections for transfer gear (bottom)
3. Support the transfer gear using engine and gearbox jack V.A.G 1383 A WE 1082 and secure with a retaining strap.
Information
Always observe the exact work sequence when installing/removing the transmission cross member.
4. Remove transmission cross member.
4.1. Unscrew bolts on the body -A-.
4.2. Unscrew two transmission cross member screws -B- on the transfer gear holder.
4.3. Remove transmission support and set it aside.
Transmission cross member
5. Place a wooden block -arrow- between the converter bell housing and suspension subframe.
Supporting transmission
6. Separate transfer gear from main transmission.
6.1. Unscrew screws used to secure the transfer gear to the main transmission at the sides and bottom.
6.2. Unscrew screws used to secure the transfer gear to the main transmission at the top. Lower the engine-transmission unit slightly using the transmission jack if necessary.
7. Press the transfer gear down off the transmission.
Removing transfer gear
8. Lower the transfer gear.
Installing transfer gear
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
Information
Tightening torque, tightening sequence and assembly overview. -> 3X00IN Tightening torque, tightening sequence and assembly overview 3X00IN Tightening torque, tightening sequence and assembly overview
1. Installation is performed in reverse order. Pay particular attention to the following:
1.1. Check that dowel sleeves for centring the transmission/transfer gear in the transmission are fitted. These must be inserted if necessary.
1.2. Always replace the O-ring for sealing the transfer gear/transmission (arrow) and oil lightly. Grease splines on the drive shaft from the transfer gear and splines on the output shaft from the transmission with lubricant for clutch plate splines (e.g. G 000 100).
Information
Do not pull the transfer gear against the transmission with the fastening screws as this can tilt the transfer gear.
1.3. Slide the transfer gear fully onto the transmission and at the same time, guide the splines of the drive shaft/transfer gear and output shaft/transmission together so that they are centred. If the splines are positioned correctly, the transfer gear will slide as far as it can go against the transmission.
Information
Always observe the exact work sequence when installing/removing the transmission cross member.
2. Install transmission cross member.
2.1. Screw in two transmission cross member screws -B- on the transfer gear holder.
2.2. Screw in bolts on the body -A-.
Transmission cross member
3. Further assembly is carried out in reverse order.
Subsequent work for transfer gear
1. Install rear cardan shaft -> 393519 Removing and installing rear cardan shaft 393519 Removing and installing rear cardan shaft
2. Install front cardan shaft -> 390219 Removing and installing front cardan shaft - section on "Installing" 390219 Removing and Installing Front Cardan Shaft
3. Remove and install exhaust system. -> 260119 Removing and installing exhaust system Service and Repair
4. Fit sound insulation under transmission and holders. -> 108019 Removing and installing engine guard 108019 Removing and installing engine guard