Transfer Case, Removing And Installing: Notes
Special tools and workshop equipment required
- Transmission Support: VW785/1B
- Bearing Installer - Multiple Use: 3062
- Transmission Support: 3282
- Engine and Gearbox Jack: VAS6931
- Grease for Clutch Disc Shaft Splines: G 000 100
Removing
-- Lift the vehicle.
-- Remove the noise insulation and bracket under the transmission. Refer to Noise Insulation .
-- Remove the rear section of the exhaust system. Refer to [For engine(s) CGFA] Exhaust System, Emission Controls , [For engine(s) CNRB] Exhaust System, Emission Controls or [For engine(s) CGRA] Exhaust System, Emission Controls .
-- Remove the rear driveshaft. Refer to REAR DRIVESHAFT, REMOVING AND INSTALLING .
-- Remove the front driveshaft. Refer to FRONT DRIVESHAFT, REMOVING AND INSTALLING .
-- Remove the exhaust system from the transmission support or the transfer case, depending on the engine. Refer to [For engine(s) CGFA] Exhaust System, Emission Controls , [For engine(s) CNRB] Exhaust System, Emission Controls or [For engine(s) CGRA] Exhaust System, Emission Controls .
-- Move the Engine and Gearbox Jack: VAS6931 with the Transmission Support: 3282 under the transmission and align it.
-- Secure the transfer case on the Transmission Support: 3282 -arrows- as illustrated. Remove the chain balancer from the transfer case beforehand, if equipped.
-- Remove the transmission support -A- from the assembly -arrows-.
-- Remove both bracket bolts -arrows- from the transmission support.
-- Remove the transmission support and lay it down.
-- Remove the side and lower bolts that connect the transfer case and transmission.
-- Slightly lower the engine/transmission assembly using the Engine and Gearbox Jack: VAS6931 if necessary.
-- Secure the engine/transmission subassembly to the body -arrows- using the Transmission Support: VW785/1B as follows:
-- Grease the Press Piece contact surface of the Transmission Support: VW785/1B with Multipurpose Grease.
-- Mount the Press Piece on the Bearing Installer - Multiple Use: 3062 . The smaller diameter of the Bearing Installer - Multiple Use: 3062 faces the Pressure Piece.
-- Place a piece of Wood -A- between the transmission and the Bearing Installer - Multiple Use: 3062 .
-- Remove the upper transfer case/transmission bolts.
-- Remove the transfer case from the transmission.
-- Lower the transfer case.
Installing
Install in reverse order of removal. Note the following:
-- Make sure the alignment sleeves for centering the engine/transfer case are installed inside the transmission. Install them if necessary.
Always replace the O-ring used for sealing the transfer case/transmission -arrow- if equipped and coat it lightly with oil.
-- Grease the input shaft splines on the transfer case and transmission with Grease for Clutch Disc Shaft Splines: G 000 100 .
-- Push the transfer case all the way onto the transmission making sure the input shaft splines/transfer case engage with the output shaft/transmission.
If the tooth position is correct and it is guided centered, the transfer case slides against the transmission as far as the stop.
Do not pull the transfer case against the transmission by the bolts otherwise the transfer case will tilt.
-- Installation is performed in reverse order of removal.
| Tightening Specification | |
|---|---|
| Transfer case to transmission | 20 Nm + 90° Always replace bolts |
| Transmission end balancer | 32 Nm |
| Chain balancer | 50 Nm |
| Bracket to transfer case, bracket to transmission support and transmission support to the assembly | TIGHTENING SPECIFICATION |