Removing and Installing

Transfer gearbox, removing and installing
Special tools and equipment





^ VAG1331 Torque wrench





^ VAG1383 A Engine/transmission jack

Removing
- Remove front exhaust pipes. Refer to Exhaust System.





- Remove heat shield -A- from vehicle underbody.
- Remove cover plate -B- (arrows).
- Disconnect drive shaft from transmission.
- Support transmission from below using transmission jack VAG1838 A and 1359/2 universal transmission mount.





- Remove right-hand bonded rubber mount protective plate -1- on transmission support.
- Remove right-hand bonded rubber mount -2-.
- Remove left-hand bonded rubber mount.
The left and right-hand (item -3-) transmission supports remain on the transmission.
- Place container under transmission.
- Drain gear oil from transfer gearbox.





- Loosen bolts -A- and -C- for transfer gearbox housing -2- using diagonal sequence and remove.
- Do not loosen bolts -B-.
- Pull transfer gearbox housing carefully toward rear off transmission, otherwise Torsen differential will fall out of transmission.





- Pull Torsen differential toward rear off output shaft.

Installing
Installation is the reverse of removal. When installing note the following:





- Make sure dowel pins (arrows -A- and -B-) are installed.
- Install gasket.
- Install cleaned magnets in cast retainer-1- in intermediate flange.





- Install Torsen differential onto output shaft splines and drive pinion of front gear wheel, rotate slightly when doing this.
- Make sure installed Torsen differential can be turned by hand.





- Install transfer gearbox housing complete with installed gears and rear drive flange onto transmission flange.
- Install bolts -A- and -C- for transfer gearbox housing -2- and tighten to torque specification using diagonal sequence.
- Fill transfer gearbox with gear oil and check oil level.





Tightening torques
Transfer gearbox housing to transmission housing: 23 Nm (17 ft. lbs.)
Protective plate to transmission: 23 Nm (17 ft. lbs.)
Bonded rubber mount to transmission support: 40 Nm (30 ft. lbs.)
Bonded rubber mount to subframe: 23 Nm (17 ft. lbs.)