Transfer Case Cover: Service and Repair

Self-Locking Center Differential Cover

Special tools, testers and auxiliary items required

• Drip tray (V.A.G 1306)

• Protective glasses

Removing

• Transmission installed.

CAUTION!
Do not let engine run or tow vehicle without gear oil.

• General repair notes. Refer to => [ General Repair Information ] General Repair Information.

• Rules of cleanliness for working on automatic transmissions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

2.0L TFSI vehicles:

• Do not bend the flex joint in the front exhaust pipe more than 10°, otherwise it will be damaged.

- Loosen bolts of front double clamp - arrows -.





- To disconnect exhaust system, slide clamping sleeve toward rear.

Vehicles with 4.2L MPI engine:

• To prevent damage, decoupling element in the front exhaust pipes must never be angled by more than 10°.

- Disconnect exhaust system at double clamps - arrows -.





- Disengage rear part of exhaust system at retaining loops and remove.

• To remove the rear section of the exhaust system, a second technician will be required.

- Remove heat shield - A - for driveshaft - arrows -.





- Remove bolts at transmission/driveshaft flange.

- Push driveshaft toward rear final drive. CV joints can be moved axially.

- Tie driveshaft up and toward the side to the heat shield - arrow -.





- Place drip tray (V.A.G 1306) underneath transmission.





CAUTION!
Wear protective glasses.

- Loosen and remove self-locking center differential cover bolts in - 6 to 1 - sequence and drain gear oil.

• The cover has no oil drain plug, so the gear oil can only be drained by removing cover.

CAUTION!
Carefully pull self-locking center differential cover off transmission toward the rear. Otherwise, the self-locking center differential can fall out of the transmission.

- Secure self-locking center differential - B - and baffle - A - against falling out or remove from output shaft toward rear.





Installing

Install in reverse order, paying attention to the following:

• Replace transfer case cover O-ring.

If the self-locking center differential - B - and baffle - A - were removed:





- Clean baffle, lubricate with gear oil and insert into transmission.

• Installation position: The plate on baffle must be secured with side tabs via opening - B - on transmission - arrow -.

- Place self-locking center differential - B - on output shaft splines while rotating slightly.





• Check installation location of baffle plate - arrow - again.

- Check whether installed self-locking center differential can be turned by hand.

- Check whether baffle plate - arrow - is still secured correctly.

- Place cover with shaft installed on self-locking center differential, rotating slightly if necessary.

- Tighten self-locking center differential cover bolts as follows:









- Install driveshaft.

- Install exhaust system tension-free.

- Fill gear oil in transfer case. Refer to => [ Transfer Case Gear Oil, Filling after Repair ] Transfer Case Gear Oil, Filling After Repair.

Tightening Specifications