Center Differential Housing and Center Differential, Bolted Driveshaft

Center Differential Housing and Center Differential, Bolted Driveshaft

Special tools, testers and auxiliary items required

• Oil Collecting and Extracting Device (V.A.G 1782)

• Sealant, refer to the Parts Catalog

Removing with Transmission Installed






It is possible to remove the center differential housing with the transmission still installed.

- Perform the vehicle-specific preliminary work.

Removing with the Transmission Removed

- Secure the transmission to the engine/transmission holder (VAS 6095). Refer to => [ Securing on Engine and Transmission Holder ] Securing On Engine and Transmission Holder.

Continuation for a Removed or Installed Transmission

- Place the (V.A.G 1782) under the transmission.






- Remove the bolts - 1 through 4 - and carefully remove the center differential housing. The Manual Transmission Fluid (MTF) will leak out while doing this.








Danger of damaging the center differential.

• Carefully and slowly pull center differential housing off of the transmission toward rear. Otherwise the center differential can fall out of the transmission.

• A center differential that has fallen out may not be installed.

- Remove the pressure spring - 3 -, shim(s) - 4 - and plate spring - 5 -.

- Pull the center differential - 2 - toward the rear.

If the gear carrier - 1 - remains in the center differential housing, proceed as follows:






Danger of damaging the sealing surface on the center differential housing.

• Use a hammer to hit the housing on several places.

- Hold the gear carrier - 1 - by one of the side ribs with pliers and remove it in - arrow A -.

- Using a rubber hammer, tap the housing on alternating sides - arrows B -.

Installing

Install in reverse order of removal. Note the following:

• Tightening specifications, refer to => [ Center Differential Housing Overview, Bolted Driveshaft ] Center Differential Housing Overview, Bolted Driveshaft.

• Replace the bolts for the center differential housing.

- Clean both housing separating surfaces thoroughly. They must be free of oil and grease.

- Apply a bead sealant - arrow 1 - evenly and not too thick on the housing surfaces; sealant. Refer to the Parts Catalog.






- Place a sealing ring round each bolt hole to prevent contact corrosion - arrow 2 -.

- Coat the gear carrier surfaces with transmission fluid MTF.

- Make sure the spacer sleeve - 2 - and the shim - 1 - are mounted on the output shaft.






- Coat both outer ring surfaces on the gear carrier slightly with MTF.






- Insert the gear carrier.

• Installed position: The tab on the gear carrier - arrow A - must fit into the opening in the transmission intermediate housing - arrow B -.

- Place the center differential - 2 - on the transmission - 1 -.






- Install the pressure spring - 3 - into the center differential.

- Attach the plate spring - 5 - and shim(s) - 4 - in the center differential housing - 6 - with a little grease.

• Plate spring installation location: The side rounded on the outside faces the flange shaft.

- Press the center differential housing centrally on until it makes contact with the transmission intermediate housing and hold it securely.






- Tighten the center differential housing bolts. Refer to => [ Tightening Specification and Sequence, Center Differential Housing - Bolted Driveshaft ] Center Differential Housing Overview, Bolted Driveshaft.

- Install the transmission.

• Check the vehicle data label or the designation on the rear final drive itself to determine which one is installed in the vehicle. Then select the correct rear final drive repair manual.

- Install the driveshaft (bolted).

- Fill with MTF.