Transfer Case, Transmissions With Separate Oil Systems, Filling After Repair
Transfer Case, Transmissions with Separate Oil Systems, Filling after Repair
Special tools, testers and auxiliary items required
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Transmission Fluid Hand Pump (VAS 6617)
• Protective eyewear
Conditions
• Axle oil temperature approximately 20 °C (68 °F) (room temperature) to max. 50 °C (122 °F).
• Vehicle level.
• The vehicle may not be started or towed without axle oil in it.
The transmission must be filled after the following work or repairs:
• The transfer case cover was removed and the gear oil was completely drained.
Refer to => [ Separate or Combined Oil Systems, Differentiation ] Separate or Combined Oil Systems, Differentiation
Procedure
• Follow all applicable disposal regulations.
• Automatic transmission clean working conditions, refer to => [ Clean Working Conditions ] Clean Working Conditions.
• General repair instructions, refer to => [ General Repair Information ] General Repair Information.
- Remove rear noise insulation by loosening bolts - 2 -, - 3 - and - 4 -.
For the following steps, note:
Do not support on the transmission oil pan or damage could result.
- Install an M12 x 100 bolt - 1 - with a nut - 2 - into the rear mount on the transmission fluid pan.
• - a - = 13 mm
- Position engine/transmission jack (V.A.G 1383 A) on bolt head and slightly raise transmission, as shown in illustration.
- Remove the sound proofing bracket from underneath the ATF cooler.
- If present, remove the electrical connector brackets - 1 - and - 2 - for the oxygen sensors from the tunnel crossmember - arrows -.
- Mark the installed position of the transmission tunnel crossmember on the body.
- Remove the left - 1 - and right - 2 - transmission bolts on tunnel crossmember.
- Remove the transmission tunnel crossmember from the body - arrows -.
- Lower or raise transmission accordingly with engine/transmission jack (V.A.G 1383 A) until transmission is horizontal in installation position again.
• The transmission must be level to check the axle oil.
• It must be raised or lowered accordingly with the (V.A.G 1383 A) after removing the tunnel crossmember.
- Slide tunnel crossmember as far back as possible so that transfer case oil inspection and filler plug - arrow - are accessible.
- Place the (V.A.G 1782) under the transmission.
Wear protective eyewear.
- Remove transfer case oil inspection and filler plug - arrow -.
• The transfer case oil inspection and filler plug is located at the side of the transfer case housing and is installed from below - arrow -.
• In the illustration, the transfer case is partially from behind so that the axle oil level with filler opening is visible.
Axle oil capacities, refer to => [ Specifications ] Table of Contents
- Fill the transfer case housing with axle oil over a period of 5 minutes through the oil fill hole in the transfer case housing - arrow - using the (VAS 6617).
• The filling time of at least 5 minutes is necessary for the internal oil level to even out.
After removing the hose, a small amount of axle oil always escapes and stands in the oil channel above the bolt.
If axle oil then drains lightly from the opening, the oil level in the transfer case is correct.
If no axle oil comes out:
- Add axle oil again until oil level is correct.
- Allow extra axle oil to drain from the oil filler hole.
• It is not necessary to check the oil level again at this stage.
- Always replace oil inspection and filler plug.
- Install new oil inspection and filler plug.
- Install tunnel crossmember. Refer to => [ Tunnel Crossmember ] Tunnel Crossmember.
Rest of installation is in reverse order of removal.
Tightening Specifications
