Transfer Case, Removing and Installing

Transfer case, removing and installing, 01V, 5 SPD. A/T (AWD)
^ Observe general repair notes.

Special tools, testers and auxiliary items required

Torque wrench 550 Nm V.A.G. 1331:

Engine-/gearbox jack V.A.G 1383 A with universal transmission support V.A.G1 359/2:

Removing
^ Remove front exhaust system with catalytic converter.





^ Remove heat shield - A - from vehicle floor.
^ Remove cover plate - B - - arrows -.
^ Disconnect propshaft from transmission.
^ Support transmission using engine-/gearbox jack V.A.G 1383 A with universal transmission support V.A.G1359/2 from below.

Vehicles with V6- and V8-engine





^ Remove bolts - B -.
^ Remove heat shield - C

All vehicles





^ Remove bolts - B -.
^ Remove heat shield - C

Continued for all vehicles





^ Lift transmission slightly using engine-/transmission jack and remove transmission mounts - D - or - H -.

Left and right transmission supports - E - remain on transmission.
^ Place drip tray VAG 1306 underneath.
^ Drain axle oil in transfer case.





^ Loosen mounting bolts - A - and - C - for transfer housing - 2 - in diagonal sequence and remove.
^ Do not loosen bolts - B -.

Carefully pull off transfer case from transmission toward the rear. Otherwise, the Torsen differential could fall out of the transmission.





^ Pull Torsen differential rearward - arrow - and off from output shaft.

Installing
Installation is performed in the reverse order of removal. Pay attention to the following:





^ Check for alignment pins - arrow A - and - arrow B -.
^ Insert new seal - D -.
^ Slide cleaned magnet into cast holding pocket - 1 - in intermediate flange.





^ Install Torsen differential onto splines of output shaft - arrow - and drive pinion for front spur gear while turning slowly.
^ Check whether installed Torsen differential can be turned by hand.
^ Install fully assembled transfer housing with installed spur gears and rear flanged shaft onto transmission flange.





^ Insert bolts - A - and - C - for transfer case - 2 - and tighten to tightening torque in stages in diagonal sequence.
^ Install left and right transmission mounts.
^ Connect propshaft to flange.
^ Install front exhaust system with catalytic converter.
^ Fill transfer case with axle oil and check oil level.