Transfer Case: Notes

Special tools and workshop equipment required

Transmission support VW 785/1B
Thrust pad 3062
Transmission support 3282
Adjustment plate 3282/37
Torque wrench VAG 1331
Torque wrench VAG 1332
Engine and transmission jack VAG 1383/A
Grease for clutch disc shaft splines G 000 100

Removing

-- Raise vehicle.

-- Remove noise insulation on bottom of transmission.

-- If an underbody impact guard is located beneath the transfer case, remove it. Refer to Description and Operation .

-- Remove the rear section of the exhaust system and, if necessary, the catalytic converters (V10 TDI):

For gas engines, refer to [For engine(s) AXQ] Description and Operation or refer to [For engine(s) BHK] Description and Operation or refer to [For engine(s) BAR] Description and Operation .
For diesel engines, refer to [For engine(s) CATA] Description and Operation or refer to [For engine(s) BWF] Description and Operation .

-- Remove the rear driveshaft. Refer to REAR DRIVESHAFT .

-- Remove the bolts for the front driveshaft at the front final drive and at the transfer case.

-- If equipped with a vibration damper -A-, remove damper from transfer case (bolts -B-).

Fig 1: Identifying Damper From Transfer Case, Remove/Install Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Before removing, mark the installation position of the damper relative to transfer case. The text "TOP" -arrow- must point upward.

-- Set up the engine and transmission holder VAG 1383/A with transmission support 3282, adjustment plate 3282/37 for "0AD" transmission and support elements as follows:

-- Place adjustment plate 3282/37 on transmission support 3282 (adjustment plate only fits in one position).

-- Align transmission support arms to correspond with the holes in adjustment plate.

The symbols on the adjusting plate indicate the support elements required, the arrow points forward.

-- Move the engine and transmission jack VAG 1383/A with transmission support 3282 under the transmission, align adjustment plate parallel to transmission and support transmission.

Fig 2: Identifying Transmission On Transmission Support 3282, Bolt & Transmission Support From Structure

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure transmission on transmission support 3282 using bolt -A-.

-- Remove transmission carrier -B- from structure.

-- Then, remove transmission carrier from transfer case bracket -arrows-.

-- Remove front driveshaft.

-- Remove side and lower transmission/transfer case bolts.

-- Disconnect connector -A- and -B- from differential motor --.

Fig 3: Identifying Connector From Differential Motor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lower engine and transmission assembly about 60 mm using the engine and transmission holder VAG 1383/A.

-- Secure engine and transmission assembly on structure -arrows- using transmission support VW 785/1B as follows:

Fig 4: Identifying Engine And Transmission Assembly On Structure With Transmission Support VW 785/1B

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lubricate contact surface of thrust pad of VW 785/1B with multi purpose grease.

-- Place thrust plate 3062 on the thrust pad. The smaller diameter of 3062 faces toward thrust pad.

-- Place a block of wood -A- between transmission and thrust pad 3062.

-- Remove transfer case/transmission upper bolts -A-.

Fig 5: Identifying Upper Transfer Case/Transmission Bolts & Breather Line From Transfer Case

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove -arrow 1- and unclip -arrow 2- breather line -B- from transfer case.

-- Separate transfer case from transmission.

-- Lower the transmission.

Fig 6: Identifying Tool Assembly To Lower Transfer Case

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing

Install in reverse sequence; note the following points:

-- Check if alignment pins for centering the transmission/transfer case are fitted in transmission; install if necessary.

Always replace O-ring seal between transfer case and transmission -arrow-. Lubricate lightly.

Fig 7: Identifying O-Ring Seal Between Transfer Case And Transmission

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Lubricate transfer case input shaft and transmission output shaft with grease for clutch disc shaft splines G 000 100.

Push transfer case completely onto transmission, ensuring that transfer case input shaft splines are centered as they are guided onto the transmission output shaft.

If splines are correctly positioned and centrally aligned, the transfer case will slide to stop against transmission.

Do not use bolts to pull transfer case onto the transmission, otherwise transfer case will distort.

-- Install front driveshaft. Refer to FRONT DRIVESHAFT .