Transmissions With Combined Oil Systems, Filling After Repair
Transmissions with Combined Oil Systems, Filling after Repair
Special tools, testers and auxiliary items required
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Engine/Transmission Jack (V.A.G 1383 A)
• Transmission Fluid Hand Pump (VAS 6617)
• Protective eyewear
Conditions
Refer to => [ Separate or Combined Oil Systems, Differentiation ] Separate or Combined Oil Systems, Differentiation
• 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 - 3 - was removed and the gear oil was completely drained.
• The front final drive cover - 6 - was removed and the gear oil was completely drained.
• The axle oil cooler - 1 - was removed.
• The oil spaces in the front final drive and transfer case are consolidated. Therefore, they must always be checked and filled together.
• Both insufficient filling and overfilling affect the transmission function.
• 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.
Procedure
The transfer case and front final drive have a combined oil system, but must be filled and checked separately in succession due to the different oil levels.
- Remove both rear noise insulators 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 (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 (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.
- Remove front final drive oil inspection and filler plug - arrow -.
Axle oil capacities, refer to => [ Specifications ] Table of Contents
- Slowly and evenly fill front final drive with axle oil over a duration of at least 5 minutes using the (VAS 6617) until oil escapes at the lower edge of the oil filler hole.
• The filling time of at least 5 minutes is necessary for the internal oil level to even out.
- 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).
Axle oil capacities, refer to => [ Specifications ] Table of Contents
• 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.
- Install the old oil inspection and filler plug.
- Install tunnel crossmember. Refer to => [ Tunnel Crossmember ] Tunnel Crossmember.
Performing a Road Test
Overfilling or underfilling the axle oil leads to transmission damage.
Follow all instructions precisely.
Before checking the oil level, a short road test must be done to bleed the oil system.
- Drive vehicle for 5 minutes at approximately 40 km/h, at least 4 km.
• Ensure the axle oil cooler is filled with transmission oil. Because the transfer case oil pump is only operated when driving, a short drive is necessary.
After the road test:
- Axle oil level, checking and adjusting. Refer to => [ Gear Oil Level in Transmission, Transmissions with Combined Oil Systems, Checking ] Gear Oil Level In Transmission, Transmissions With Combined Oil Systems, Checking
Tightening Specifications
