Transfer Case Assembly Overview

Fig 1: Identifying Seals For Output Flange/Driveshaft And Differential Motor, Remove/Install Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Nut, 130 Nm
- Always replace.
- Removing, refer to REMOVE OUTPUT FLANGE NUT. .
- Installing, refer to TIGHTEN NEW NUT FOR OUTPUT FLANGE TO SPECIFICATION. .
- Securing, refer to SECURE NUT AT INTENDED POINTS -ARROWS- (E.G., WITH A DRIFT). .
- Insert with Loctite 648.
O-ring
- Always replace.
- Insert with gear oil, refer to LUBRICATE NEW O-RING -ARROW- WITH GEAR OIL AND INSERT. .
Output flange
- For rear driveshaft.
- Removing and installing, refer to REAR DRIVESHAFT OUTPUT FLANGE SEAL, WITH TRANSFER CASE INSTALLED .
Dust plate
- For output flange.
- Pressing off, refer to Figure
- Pressing on, refer to Figure
Oil seal
- For rear driveshaft output flange.
- Pulling out, refer to Figure
- Driving in, refer to Figure
- Replacing with transmission installed, refer to REAR DRIVESHAFT OUTPUT FLANGE SEAL, WITH TRANSFER CASE INSTALLED .
Breather pipe
- Removing, refer to Figure
- Installing, refer to Figure
Input shaft seal
- Removing and installing, refer to INPUT SHAFT SEAL .
O-ring
- Always replace.
- Insert into groove of input shaft, refer to Figure
Nut, 130 Nm
- Always replace.
- Removing, refer to REMOVE THE OUTPUT FLANGE NUT .
- Installing, refer to TIGHTEN NEW NUT FOR OUTPUT FLANGE TO SPECIFICATION .
- Securing, refer to SECURE NUT AT INTENDED POINTS -ARROWS- (E.G., WITH A DRIFT) .
- Insert with Loctite 648.
O-ring
- Always replace.
- Insert with gear oil, refer to LUBRICATE NEW O-RING -ARROW- WITH GEAR OIL AND INSERT .
Output flange
- For front driveshaft.
- Removing and installing, refer to FRONT DRIVESHAFT OUTPUT FLANGE SEAL, WITH TRANSFER CASE INSTALLED .
Dust plate
- For output flange.
- Pressing off, refer to Figure
- Pressing on, refer to Figure
Oil seal
- For front driveshaft output flange.
- Pulling out, refer to Figure
- Driving in, refer to Figure
- Replacing with transmission installed, refer to FRONT DRIVESHAFT OUTPUT FLANGE SEAL, WITH TRANSFER CASE INSTALLED .
O-ring
- Must rest in the groove of the differential motor -V253-
Alignment bushing
- Quantity: 2
- For aligning the differential motor -V253- on transfer case.
Differential motor -V253-
- Removing and installing, refer to DIFFERENTIAL MOTOR .
- The following components are integrated into the differential motor -- : differential position sensor -G398-, differential position sensor 2 -G482-, motor temperature sensor -G407-, brake for locking motor -- and oil temperature sensor -G8-
- Differential motor -- and integrated components can be tested via "Guided fault Finding"
- When replacing differential motor --, the oil temperature sensor -G8- must also be replaced, refer to item 24 and Figure.
- As of 02.05, the differential motor -- is available only together with clamp, refer to "Bracket" in item 19.
Bolt, 27 Nm
Bolt, 14 Nm
Bracket
- For securing the differential motor -V253- to the transfer case.
- No longer available as separate part as of 02.05
Oil drain plug, 20 Nm
- Always replace.
Bolt, 20 Nm
Bolt, 20 Nm
Bracket
- Removing and installing, refer to TRANSMISSION CARRIER AND BRACKET .
Oil temperature sensor -G8-, 17 Nm
- On certain transmissions, a sealing plug may also be installed, refer to Figure
- The discontinuation of the oil temperature sensor -- occurred shortly after start of production, while simultaneously transfer cases were introduced that were no longer equipped with a hole in the housing for the oil temperature sensor --.
- Repair solution for defective oil temperature sensor --, refer to Figure
Oil seal
- Always replace
Oil filler plug, 20 Nm
- Always replace
Bolt, 32 Nm
Vibration damper
- Equipped on some transmissions.
- Observe installed location, refer to IF EQUIPPED, INSTALL VIBRATION DAMPER -A- TO TRANSFER CASE AND TIGHTEN BOLTS -B- .
Transfer case