00 GENERAL, TECHNICAL DATAkankondemuamba.a.k.f.unblog.fr/files/2012/04/rear-differential.pdf · Code letters GJJ GJK 2006 Volkswagen Touareg REAR DIFFERENTIAL Rear Final Drive Microsoft

REAR DIFFERENTIAL

Rear Final Drive

00 GENERAL, TECHNICAL DATA

DRIVETRAIN GUIDE

Fig. 1: Drivetrain Guide, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Transfer case

Transfer case, removing and installing --> Differential, removing and installing

2 - Drive shafts

2006 Volkswagen Touareg

REAR DIFFERENTIAL Rear Final Drive



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Sunday, September 20, 2009 9:03:51 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.

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Drive shafts, removing and installing --> Driveshafts, removing and installing

3 - Rear final drive

Rear final drive, removing and installing --> Rear final drive, removing and installing

4 - Front final drive

Front final drive, removing and installing --> Front final drive, removing and installing

TRANSFER CASE IDENTIFICATION

Transfer case identification

The transfer case 0AD is allocated to the automatic transmission 09D.

Off-road reduction gearing is integrated into the transfer case.

Switching between street gearing "HIGH" and off-road gearing "LOW" is accomplished with the transfer case operating unit E473.

Code letters --> Code letters, transmission allocation, gear ratios, capacities.

Location on transfer case

Location on transfer case - arrow -

Fig. 2: Location On Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Code letters - arrow 1 - and date of manufacture - arrow 2 - of transfer case



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Fig. 3: Code Letters And Date Of Manufacture Of Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Additional data depends on manufacture.

Code letters, transmission allocation, gear ratios, capacities

Example GJJ 03 05 02 I I I I I I I I Code letters Day Month Year (2002) of

manufacture

Transfer case 0ADCode letters FKA FKBApplication Model Touareg 2003 --> Touareg 2003 --> Engine 4.2 L - 228 kW 5.0 L -

230 kW Turbo-Diesel3.2 L -162 kW

Transmission housing extension length 127.4 mm 139.9 mmCapacities 0.85 liters

Transfer case 0ADCode letters FKC GFG GFHApplication Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 4.2 L - 228 kW 4.9

L - 230 kW Turbo-Diesel

3.2 L -162 kW

Transmission housing extension length 158.2 mm 127.4 mm 158.2 mmCapacities 0.85 liters

Transfer case OADCode letters GJJ GJK



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Application Model Touareg 2003 --> Touareg 2003 --> Engine 4.2 L - 228 kW 5.0 L -

230 kW Turbo-Diesel3.2 L -162 kW

Transmission housing extension length 127.4 mm 139.9 mmCapacities 0.85 liters

Transfer case 0ADCode letters GJL GTMApplication Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 5.0 L - 230 kW Turbo-

DieselTransmission housing extension length 158.2 mm 127.4 mmCapacities 0.85 liters

Transfer case 0ADCode letters GTN GTP HCHApplication Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2 L

- 177 kW3.2 L -162 kW 3.2 L - 177 kW

5.0 L - 230 kW Turbo-Diesel

Transmission housing extension length 139.9 mm 158.2 mm 127.4 mmCapacities 0.85 liters

Transfer case OADCode letters HPW HPXApplication Model Touareg 2003 --> Touareg 2003 --> Engine 5.0 L - 230 kW Turbo-

Diesel5.0 L - 230 kW Turbo-Diesel

Transmission housing extension length 127.4 mm 127.4 mmCapacities

Transfer case OADCode letters HMXApplication Model Touareg 2003 --> Engine 3.2 L -177 kWTransmission housing extension length 158.2 mmCapacities 0.85 liters

Transfer case 0ADCode letters HXB HXE HXAApplication Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 5.0 L - 230 kW 3.2 L -177 kW 4.2 L -228 kW 4.2 L



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FRONT FINAL DRIVE IDENTIFICATION

Front final drive identification

The front final drive 0AA is allocated to the automatic transmission 09D.


Front final drive identification, location

Location on front final drive - arrow -.

Fig. 4: Location On Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turbo-Diesel -257 kWTransmission housing extension length 127.4 mm 158.2 mm 127.4 mmCapacities 0.85 liters

Transfer case 0ADCode letters HXC FKFApplication Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -177 kW 3.2 L -177 kWTransmission housing extension length 139.9 mm 139.9 mmCapacities 0.85 liters

Transfer case 0ADCode letters FKG FKFApplication Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -177 kW 3.2 L -177 kWTransmission housing extension length 139.9 mm 139.9 mmCapacities 0.85 liters



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Code letters and date of manufacture of front final drive.

Fig. 5: Identifying Code Letters And Date Of Manufacture Of Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.



Example FKK 20 08 02 I I I I I I I I Code letters Day Month Year (2002) of

manufacture

Front final drive 0AACode letters FKK FKM FKN

Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 4.2 L - 228 kW 3.2 L -162 kW 3.2 L

-177 kW4.2 L -228 kW

Gear ratio: Z 1 : Z 2 Final drive 37 : 10 = 3.700 39 : 10 = 3.900 41 :10 = 4.100

Capacities 1.0 litersDrive shaft flange dia. 114 mm 114 mm 114 mmElectromechanical differential lock Without Without Without

Front final drive 0AACode letters FKQ FLH FLJ

Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2 L

-177 kW3.2 L -162 kW 3.2 L -162 kW 3.2 L

-177 kWGear ratio: Z 1 : Z 2 Final drive 41 : 9 = 4.556 39 : 10 = 3.900 41 : 9 = 4.556

Capacities 1.0 liters



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Drive shaft flange dia. 114 mm 114 mm 114 mmElectromechanical differential lock Without With With

Front final drive 0AACode letters FVX FVZ GFA

Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 5.0 L - 230 kW

Turbo-Diesel4.2 L - 257 kW 5.0 L - 230 kW

Turbo-DieselGear ratio: Z 1 : Z 2 Final drive 36 : 11 = 3.273 43 : 10 = 4.300 36 : 11 = 3.273


Front final drive 0AACode letters GFB GLZ

Application Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2L - 177

kW5.0 L - 230 kW Turbo-Diesel

Gear ratio: Z 1 : Z 2 Final drive 41 : 9 = 4.556 36 : 11 = 3.273

Capacities 1.0 litersDrive shaft flange dia. 114 mm 122 mmElectromechanical differential lock Without Without

Front final drive 0AACode letters GMC GMN GNJ

Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2 L

-177 kW4.2 L -228 kW 4.9 L - 230 kW



Front final drive OAACode letters GNL GNM

Application Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L - 177 kW 4.5 L -

250 kW3.2 L -162 kW 3.2 L -177 kW


Capacities 1.0 liters



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REAR FINAL DRIVE IDENTIFICATION

Rear final drive identification

The rear final drive 0AB/0AC is allocated to the automatic transmission 09D.


Location on rear final drive

Location on rear final drive - arrow -.

Fig. 6: Location On Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Code letters and date of manufacture of rear final drive.

Drive shaft flange dia. 114 mm 114 mmElectromechanical differential lock Without Without



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Fig. 7: Code Letters And Date Of Manufacture Of Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.



Example FKY 20 08 02 I I I I I I I I Code letters Day Month Year (2002) of

manufacture

Rear final drive 0AB/0ACCode letters FKS FKU FKV

Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 4.2 L -228 kW 3.2 L -162 kW 3.2 L

- 177 kW 3.2 L - 206 kW

4.2 L -228 kW

Gear ratio: Z 2 : Z 1 Final drive 37 : 10 = 3.700 39 : 10 = 3.900 41 : 10 = 4.100


Rear final drive 0AB/0ACCode letters FKW FLM



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Rear final drive "FWG" : In conjunction with automatic transmission 09D = drive axle flange dia. 112 mm.

Application Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2 L -162 kWGear ratio: Z 2 : Z 1 Final drive 41 : 9 = 4.556 39 : 10 = 3.900

Capacities 1.25 liters 1.6 litersDrive shaft flange dia. 112 mm 112 mmElectromechanical differential lock Without With

Rear final drive 0AB/0ACCode letters FLN FLP

Application Model Touareg 2003 --> Touareg 2003 --> Engine 4.2 L - 228 kW 3.2 L -162 kWGear ratio: Z 2 : Z 1 Final drive 41 : 10 = 4.100 41 : 9 = 4.556

Capacities 1.6 litersDrive shaft flange dia. 118 mm 112 mmElectromechanical differential lock With With

Rear final drive 0AB/0AC 0AB/0ACCode letters FLT FWC FWG

Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L - 177 kW 4.2

L -228 kW5.0 L - 230 kW Turbo-Diesel

4.2 L - 228 kW


Capacities 1.6 liters 1.25 liters 1.6 litersDrive shaft flange dia. 118 mm 118 mm 112 mm/118 mmElectromechanical differential lock With Without With

Rear final drive 0AB/0ACCode letters FWH GFC GFD

Application Model Touareg 2004 --> Touareg 2004 --> Touareg 2004 --> Engine 5.0 L - 230 kW

Turbo-Diesel3.2 L -162 kW 5.0 L - 230 kW


Capacities 1.6 liters 1.25 liters 1.25 litersDrive shaft flange dia. 118 mm 112 mm 118 mmElectromechanical differential lock With Without Without

Rear final drive 0AB/0ACCode letters GLP



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Application Model Touareg 2004 --> Engine 3.2 L -162 kW 3.2 L -177 kWGear ratio: Z 2 : Z 1 Final drive 39 : 10 = 3.900

Capacities 1.25 litersDrive shaft flange dia. 112 mmElectromechanical differential lock Without

Rear final drive 0AB/0ACCode letters GLQ GLR GLS

Application Model Touareg 2004 --> Touareg 2004 --> Touareg 2004 --> Engine 4.2 L -228 kW 3.2 L -162 kW 3.2 L

-177 kW5.0 L - 230 kW Turbo-Diesel



Rear final drive 0AB/0ACCode letters GMP GMQ


Capacities 1.25 liters 1.6 litersDrive shaft flange dia. 118 mm 118 mmElectromechanical differential lock Without With

Rear final drive 0AB/0ACCode letters GNN HLQ

Application Model Touareg 2004 --> Touareg 2004 --> Engine 5.0 L - 230 kW Turbo-



Capacities 1.6 liters 1.6 litersDrive shaft flange dia. 118 mm 118 mmElectromechanical differential lock With With

Rear final drive 0AB/0ACCode letters HLU HLV

Application Model Touareg 2004 --> Touareg 2004 --> Engine 3.2 L -177 kW 4.2 L -228 3.2 L -162 kW 3.2 L -177



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kW kWGear ratio: Z 2 : Z 1 Final drive 41 : 09 = 4.556 41 : 09 = 4.556

Capacities 1.6 litersDrive shaft flange dia. 118 mm 112 mmElectromechanical differential lock With With

Rear final drive 0AB/0ACCode letters FLA GLV


Capacities 1.6 litersDrive shaft flange dia. 112 mm 112 mmElectromechanical differential lock Without Without

Rear final drive 0AB/0ACCode letters FLA JAJ GLV

Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2L - 177 kW 5.0 L - 230 kW

Turbo-Diesel3.2L - 177 kW


Capacities 1.6 liters 1.6 liters 1.6 litersDriveshaft flange dia. 112 mm 114 mm 112 mmElectromechanical differential lock Without With Without

Rear final drive 0AB/0ACCode letters JLP JLQ




Capacities 1.6 liters 1.6 litersDriveshaft flange 118 mm 118 mmElectromechanical differential lock Without With

Rear final drive 0AB/0ACCode letters JLP JLQ





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GENERAL REPAIR INSTRUCTIONS

General repair instructions

To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. The usual basic safety precautions also, apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the article, are summarized here under the topic "Components" --> Components. They apply to this article.

Components

Transmission

When installing the transfer case, make sure that the alignment sleeves between the transmission and transfer case are correctly positioned.

When assembling mounting brackets as well as other waxed components the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.

When exchanging a transfer case, the gear oil must be filled up to lower edge of filler hole.

Capacities in transfer case --> Code letters, transmission allocation, gear ratios, capacities.

When exchanging a front final drive, the gear oil must be filled up to lower edge of filler hole.

Capacities in front final drive --> Code letters, transmission allocation, gear ratios, capacities.

When exchanging a rear final drive, the gear oil must be filled up to lower edge of filler hole.

Capacities in rear final drive --> Code letters, transmission allocation, gear ratios, capacities.


Capacities 1.6 liters 1.6 litersDriveshaft flange dia. 118 mm 118 mmElectromechanical differential lock Without With

Rear final drive 0AB/0ACCode letters HEX JMB


Capacities 1.6 liters 1.6 litersDriveshaft flange dia. 118 mm 118 mmElectromechanical differential lock With With



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Gaskets, seals

Replace O-rings.

Radial shaft seals.

Before installing:

Fig. 8: Identifying Space Between Oil Seal Sealing Lips Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lightly lubricate outer edge and fill space between sealing lips - arrow - halfway with grease G 052 128 A1 .

After installation:

Check gear oil level in transfer case --> Gear oil level in transfer case, checking.

Check gear oil level in front final drive --> Gear oil in front final drive, checking.

Check gear oil level in rear final drive --> Gear oil in rear final drive, checking.

Locking elements

Replace circlip.

Do not overstretch circlips.

Circlips must be properly seated in the base of the groove.

Bolts and nuts

Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.

The tightening torques stated apply to unoiled bolts and nuts.

Replace self-locking bolts and nuts.

Make sure with bolted connections that the contact surfaces as well as the visible surfaces of nuts and bolts are rewaxed after assembly, if necessary.

Use a thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be installed. Otherwise there is a risk that the bolts will shear the next time they are removed.



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Bearings

Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.

Guided fault finding, On Board Diagnostic (OBD) and measuring technology

Fig. 9: VAS 5051 Vehicle Diagnosis, Testing and Information System Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before replacing the differential motor V253 of the transfer case and, on vehicles with differential lock on rear final drive, the differential lock motor V304 , the cause of the damage can likely be determined using the vehicle diagnostic, testing and information system VAS 5051 in the operating mode "Guided Fault-finding" , "On Board Diagnostics" and "Measuring technology".

34 CONTROLS, HOUSING

ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLED LOCATIONS FOR TRANSFER CASE

Electrical/electronic components and installed locations for transfer case



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Fig. 10: Electrical/Electronic Components And Installed Locations For Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Differential control module J646

Location --> Location of Differential control module J646

Removing and installing --> Differential control module J646 , removing and installing

2 - Transfer case operating unit E473

Location --> Location of transfer case operating unit E473

Removing and installing --> Location of transfer case operating unit E473

3 - Differential motor V253

Removing and installing --> Differential motor V253 , removing and installing



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The following components are integrated into the differential motor V253 :

Differential position sensor G398

Differential position sensor 2 G482

Motor temperature sensor G407

Brake for locking motor

4 - Data Link Connector (DLC)

Installed location --> Data Link Connector (DLC)

5 - Closed throttle position (CTP) switch F60

Only installed on vehicles with manual transmission

Installed location --> Location of closed throttle position (CTP) switch F60

Removing and installing --> Location of closed throttle position (CTP) switch F60

6 - Multi-function display in instrument cluster

Indicates condition and information about longitudinal lock and off-road gearing in transfer case

Location of Differential control module J646

Fig. 11: Location Of Differential Control Module J646 Courtesy of VOLKSWAGEN UNITED STATES, INC.

The differential control module J646 is located under the right front seat - arrow B -.

Differential control module J646 , removing and installing --> Differential control module J646 , removing and installing.

Location of transfer case operating unit E473



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Fig. 12: Location Of Transfer Case Operating Unit E473 Courtesy of VOLKSWAGEN UNITED STATES, INC.

The transfer case operating unit E473 - 1 - is located in shift cover - 2 - of center console.

Transfer case operating unit E473 , removing and installing --> 70 - INTERIOR TRIM .

Data Link Connector (DLC)

Fig. 13: Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.

The Data Link Connector (DLC) is located in the cover of the drivers side footwell.

Location of closed throttle position (CTP) switch F60



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Fig. 14: Location Of Closed Throttle Position (CTP) Switch F60 Courtesy of VOLKSWAGEN UNITED STATES, INC.

The closed throttle position (CTP) switch F60 - 1 - is located in the area of the shift cover with switching rockers on the manual transmission - 2 -.

Differential control module J646 , removing and installing

Removing

Remove right front seat --> 72 - SEAT - FRAMES .

If equipped, remove cover from seat frame.

First check whether a coded radio is installed. If this is the case obtain the anti-theft coding.

Switch ignition and all electrical consumers off, and remove ignition key.

Disconnect Ground (GND) terminal connector from battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig. 15: Separating Connector At Differential Control Module J646 And Connector At Transmission Control Module J217 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate connector - 1 - at differential control module J646 and, if equipped, connector - 2 - at



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transmission control module J217.

Remove bolt - 3 -.

Pull the retainer with differential control module J646 in direction of - arrow - out of bracket on seat frame.

Fig. 16: Pressing Retaining Tabs And Pulling Differential Control Module J646 Out Of Retainer Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press retaining tabs - 1 - in direction of - arrow - and pull differential control module J646 out of retainer. Make sure that the differential control module J646 does not fall to floor.

Installing

Installation in reverse order of removal. Note the following:

Fig. 17: Pushing Retainer For Differential Control Module J646 With Latches Into Recesses Of Seat Frame Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push retainer for differential control module J646 with latches - 2 - into recesses - 1 - of seat frame.

Fasten bolt - 3 - to 8 Nm.

Connect Ground (GND) terminal connector to battery and perform work sequences after connecting battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .



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DIFFERENTIAL, REMOVING AND INSTALLING

Differential, removing and installing

Fig. 18: Identifying Special Tools - Differential, Removing And Installing (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Transmission support VW 785/1B

Adapter 10 - 222 A/7

Lifting tackle 2024 A

Thrust pad 3062

Transmission support 3282



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Adjustment plate 3282/37

Fig. 19: Identifying Special Tools - Differential, Removing And Installing (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.


Torque wrench V.A.G 1331


Engine/transmission jack V.A.G 1383/A

Grease for clutch disc shaft splines G 000 100

Transfer case, removing

Raise vehicle.



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Remove sound insulation on bottom of transmission.

If an underbody impact guard is located beneath the transfer case, remove it --> 50 - BODY - FRONT .

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

26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX

26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK

26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR

26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX

26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF

.

Remove rear driveshaft --> Rear driveshaft, removing and installing.

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

Fig. 20: Removing Damper From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Set up engine/transmission jack V.A.G 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 arms of transmission support according to holes in adjustment plate.

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



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Fig. 21: Securing Transmission On Transmission Support 3282 Using Bolt & Removing Transmission Support From Structure Courtesy of VOLKSWAGEN UNITED STATES, INC.

Move engine/transmission jack V.A.G 1383/A with transmission support 3282 under transmission, align adjustment plate parallel to transmission and support transmission.

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

Remove transmission support - B - from structure.

Unbolt transmission support from transfer case console - arrows -.

Remove front driveshaft.

Remove side and lower transmission/transfer case bolts.

Fig. 22: Disconnecting Connector From Differential Motor Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Lower engine and transmission assembly about 60 mm using engine/transmission jack V.A.G 1383/A.



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Fig. 23: Securing Engine And Transmission Assembly On Structure With Transmission Support VW 785/1B Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

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

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

Fig. 24: Removing Upper Transfer Case/Transmission Bolts & Uncliping Breather Line From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove upper transfer case/transmission bolts - A -.

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

Press transfer case off from transmission.



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Fig. 25: Lowering Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lower transfer case.

Transfer case, transporting

Fig. 26: Attaching Engine Sling 2024A As Follows To Lifting Eyes Of Transfer Case And Transport With Workshop Crane Courtesy of VOLKSWAGEN UNITED STATES, INC.

Attach engine sling 2024A as follows to lifting eyes of transfer case and transport with workshop crane.

Input shaft side:

4. Hole for hook in position 1 of engine sling - arrow A -.

Output shaft side (driveshaft flange):

2. Hole for hook rail in position 8 of engine sling - arrow B -.

CAUTION: The hooks and locating pins must be secured with locking pins.



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Transfer case, installing

Install in reverse order, paying attention to the following:

Check if alignment sleeves for centering the transmission/transfer case are installed in transmission; install if necessary.

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

Fig. 27: Identifying O-Ring Seal Between Transfer Case And Transmission Courtesy of VOLKSWAGEN UNITED STATES, 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 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 be distorted.

Install front driveshaft --> Front driveshaft, removing and installing.



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Fig. 28: Removing/Installing Damper From/To Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

If equipped, install damper - A - to transfer case and fasten bolts - B -.

The text "TOP" - arrow - must point upward.

Install rear driveshaft --> Rear driveshaft, removing and installing.

If an underbody impact guard is located beneath the transfer case, install it --> 50 - BODY - FRONT .


Install exhaust system -->






.

Tightening torques

Console to transfer case, console to transmission and transmission support to structure.

Routing of breather line on transfer case

Transfer case to transmission 45 NmDamper to transfer case 32 Nm



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Fig. 29: Routing Of Breather Line On Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

The breather line - 1 - for the transfer case runs over the transfer case and manual transmission to coolant hose - 4 -.

The breather line is clipped into the retainer - 2 - on the transfer case and retainer - 3 - on the manual transmission.

The illustration shows routing of the line with a manual transmission. The routing of the line with an automatic transmission is similar.

TRANSMISSION CARRIER AND CONSOLE, REMOVING AND INSTALLING

Transmission carrier and console, removing and installing



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Fig. 30: Identifying Special Tools - Transmission Carrier And Console, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.




Engine/transmission jack V.A.G 1383 A with universal transmission adapter V.A.G 1359/2

Transmission carrier and console, removing

Raise vehicle.

Remove sound insulation below transmission.

If an underbody impact guard is located beneath transmission carrier and console, remove it --> 50 - BODY - FRONT .



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Fig. 31: Removing Bolts For Transmission Support From Transfer Case Console Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place engine/transmission jack V.A.G 1383 A with universal adapter V.A.G 1359/2 and a block of wood - A - under transfer case.

Do not loosen bolts - arrows - yet.

Fig. 32: Unbolting/Tightening Transmission Carrier From/To Structure Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt transmission carrier - A - from structure - arrows -.

Lower transfer case slightly, until transmission carrier hangs freely.



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Remove bolts for transmission support from transfer case console - arrows -.

Fig. 34: Unbolting Console From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt console - A - from transfer case - arrows -.

Transmission carrier and console, installing

Install is performed in the reverse order of removal.

Tightening torques

Due to the various engine variations and differing lengths of the transfer case extension, there are various consoles and transmission carriers. Allocation depends on the engine installed .

The various options result in the following fastening points for console to transfer case and transmission carrier

Console to transmission carrier

Always replace bolts

50 Nm plus an additional 90° (1 /4 turn



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to structure:

Vehicles with 6 and 8-cylinder engine.

Fig. 35: Identifying Fastening Points For Console To Transfer Case And Transmission Carrier To Structure (Vehicles With 6 And 8-Cylinder Engine) Courtesy of VOLKSWAGEN UNITED STATES, INC.


*Always replace bolts

Vehicles 10-cylinder engine

Console to transfer case Bolts - 1 - M8 x 35 20 NmBolts - 2 - M8 x 70 20 Nm

Transmission carrier to structure


Bolts - 3 - M10 x 80 * See note 50 Nm plus an additional 90° 1 /4 turn



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Fig. 36: Identifying Fastening Points For Console To Transfer Case And Transmission Carrier To Structure (Vehicles 10-Cylinder Engine) Courtesy of VOLKSWAGEN UNITED STATES, INC.


If an underbody impact guard is located beneath transmission carrier and console, install it --> 50 - BODY - FRONT .

BONDED RUBBER BUSHING IN TRANSMISSION CARRIER, REPLACING

Bonded rubber bushing in transmission carrier, replacing

Console to transfer case Bolts - 1 - M8 x 35 20 NmBolts - 2 - M8 x 70 20 Nm

Transmission carrier to structure


Bolts - 3 - M10 x 80 50 Nm plus an additional 90° 1 /4 turn



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Fig. 37: Identifying Special Tools - Bonded Rubber Bushing In Transmission Carrier, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.


Pressure plate VW 402

Punch VW 412

Thrust plate VW 432

Base block VW 441

Tube 3296

Alignment fixture T10214

Remove transmission carrier --> Transmission carrier and console, removing and installing.



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Fig. 38: Pressing Out Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing out bonded rubber bushing.

Fig. 39: Pressing New Bonded Rubber Bushing With Pressure Piece T10214/3 Into Guide Sleeve T10214/2 , Until Pressure Piece T10214/3 Is Flush With Guide Sleeve T10214/2 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect new bonded rubber bushing with pressure piece T10214/3.

Press new bonded rubber bushing - A - with pressure piece T10214/3 into guide sleeve T10214/2 , until pressure piece T10214/3 is flush with guide sleeve T10214/2.



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Fig. 40: Aligning Bonded Rubber Bushing To Transmission Carrier, Using Assembly Tool T10214 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Align bonded rubber bushing to transmission carrier, using assembly tool T10214.

To align bushing, align bolts - A - and/or notch - arrow - on pressure piece T10214/3 centrally to holes in transmission carrier.

Spacing "x" must be equal.

Fig. 41: Pressing Bonded Rubber Bushing Into Transmission Carrier, Until Guide Sleeve T10214/2 Can Be Turned By Hand Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press bonded rubber bushing into transmission carrier, until guide sleeve T10214/2 can be turned by hand - arrows -.

Do not press the bonded rubber bushing any deeper into the transmission carrier than the height of the tube 3296. If necessary press further with base block VW 441 up to stop.

Install transmission carrier --> Transmission carrier and console, removing and installing.

GEAR OIL LEVEL IN TRANSFER CASE, CHECKING



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Gear oil level in transfer case, checking

Transmission oil specification --> Code letters, transmission allocation, gear ratios, capacities


Fig. 42: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Fig. 43: Removing Sealing Plug For Gear Oil Inspection Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove sealing plug for gear oil inspection - arrow -.

Oil level is correct when the transfer case is filled up to lower edge of oil filler hole.

Insert new plug - arrow - and fasten.

When initially filling transfer case:

Remove plug - arrow -.



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Top off oil to lower edge of filler hole.

Insert new plug - arrow - and fasten.

SEALS FOR OUTPUT FLANGE/DRIVESHAFT AND DIFFERENTIAL MOTOR , REMOVING AND INSTALLING

Seals for output flange/driveshaft and differential motor , removing and installing

Fig. 44: Identifying Special Tools - Seals For Output Flange/Driveshaft And Differential Motor , Removing And Installing (1 Of 3) Courtesy of VOLKSWAGEN UNITED STATES, INC.


Tightening torque: Oil filler plug 20 Nm



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Holding fixture VW 313


Punch VW 408 A

Holding fixture VW 540

Slide hammer VW 771

Pulling hook VW 771/37



Thrust pad 30 - 504



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Tube 32 - 119

Thrust pad 3062



- 3 - - Kukko 17/2 Separating device



Thrust plate T10185

Thrust plate T10203



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Socket T10204

Wiring harness repair kit VAS 1978

Loctite 648

Tension transfer case in assembly fixture --> Secure transfer case to assembly stand with bolts

Fig. 47: Seals For Output Flange/Driveshaft And Differential Motor Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Nut, 130 Nm

Always replace

Removing --> Fig. 71

Installing --> Fig. 75



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Securing --> Fig. 69

Insert with Loctite 648

2 - O-ring

Always replace

Insert with gear oil --> Fig. 74

3 - Output flange

For rear driveshaft

Removing and installing --> Output flange oil seal for rear driveshaft, replacing (transfer case installed)

4 - Dust plate

For output flange

Pressing off --> Pressing off dust plate

Pressing on --> Pressing on dust plate to stop

5 - Seal

For output flange/rear driveshaft

Pulling out --> Pulling out oil seal for output flange/rear driveshaft

Driving in --> Driving in oil seal for output flange/rear driveshaft

Replacing with transmission installed --> Output flange oil seal for rear driveshaft, replacing (transfer case installed)

6 - Breather pipe

Removing Remove breather tube

Driving in --> Driving in breather tube

7 - Input shaft oil seal

Removing and installing --> Input shaft seal, replacing

8 - O-ring

Always replace

Insert into groove of input shaft --> Insert into O-ring into groove of input shaft

9 - Nut, 130 Nm



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Always replace

Removing --> Fig. 65

Installing --> Fig. 68

Securing --> Fig. 69

Insert with Loctite 648

10 - O-ring

Always replace

Insert with gear oil --> Fig. 74

11 - Output flange

For front driveshaft

Removing and installing --> Output flange oil seal for front driveshaft, replacing (transfer case installed)

12 - Dust plate

For output flange

Pressing off --> Pressing off dust plate

Pressing on --> Pressing on dust plate to stop

13 - Seal

For output flange/front driveshaft

Pulling out --> Pulling out oil seal for output flange/rear driveshaft

Driving in --> Driving in oil seal for output flange/front driveshaft

Replacing with transmission installed --> Output flange oil seal for front driveshaft, replacing (transfer case installed)

14 - O-ring

Must rest in groove of Differential Motor V253

15 - Alignment bushing

Qty. 2

For aligning differential motor on transfer case

16 - Differential motor V253

Removing and installing --> Differential motor V253 , removing and installing



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The following components are integrated into 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 with "Guided fault-finding"

17 - Bolt, 27 Nm

18 - Bolt, 14 Nm

19 - Clamp

For fastening differential motor V253 on transfer case

No longer available as separate part as of 02.05

20 - Oil drain plug, 20 Nm

Always replace

21 - Bolt, 20 Nm

22 - Bolt, 20 Nm

23 - Console

Removing and installing --> Transmission carrier and console, removing and installing

24 - Engine oil temperature sensor G8 , 17 Nm

On certain transmissions, a sealing plug may also be installed --> Repair solution for replacement of Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8

The discontinuation of engine oil temperature sensor occurred shortly after start of production. Transfer cases were introduced that were no longer equipped with a hole in the housing for the engine oil temperature sensor.

Repair solution for faulty engine oil temperature sensor --> Repair solution for replacement of Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8

25 - Seal

Always replace

26 - Oil filler plug, 20 Nm

Always replace

27 - Bolt, 32 Nm



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28 - Vibration damper

Not in all transmissions

Observe installed location --> Fig. 28

29 - Transfer case

Secure transfer case to assembly stand with bolts

Fig. 48: Securing Transfer Case To Assembly Stand With Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing off dust plate

Fig. 49: Pressing Off Dust Plate Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Separating device 22 to 115 mm, e.g. Kukko 17/2

Pressing on dust plate to stop



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Fig. 50: Pressing On Dust Plate To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling out oil seal for output flange/rear driveshaft

Fig. 51: Pulling Out Sealing Ring Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Figure shows seal for output flange/rear driveshaft being pulled out.

The procedure for pulling out oil seal for output flange/front driveshaft is identical.

Driving in oil seal for output flange/rear driveshaft



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Fig. 52: Driving In Oil Seal For Output Flange/Rear Driveshaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .

Insert into O-ring into groove of input shaft

Fig. 53: Identifying O-Ring Seal Between Transfer Case And Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing on dust plate to stop



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Fig. 54: Pressing On Dust Plate To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

Driving in oil seal for output flange/front driveshaft

Fig. 55: Driving New Seal In As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.


Remove breather tube

Fig. 56: Removing Breather Tube Courtesy of VOLKSWAGEN UNITED STATES, INC.

Guide 5 mm diameter drift - B - into hole of breather pipe.

Move breather pipe - A - in direction of arrow while simultaneously prying breather tube out of transfer case using screwdriver - C -.

Driving in breather tube



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Fig. 57: Driving In Breather Tube Courtesy of VOLKSWAGEN UNITED STATES, INC.

Coat breather tube with locking fluid Loctite 648 before driving in.

Repair solution for replacement of Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8

Fig. 58: Repairing Solution For Replacement Of Differential Motor V253 And For Malfunctioning Oil Temperature Sensor G8 Courtesy of VOLKSWAGEN UNITED STATES, INC.

When replacing Differential Motor V253 and when Oil Temperature Sensor - 4 - is malfunctioning, the Oil Temperature Sensor (with sealing ring - 3 -) is replaced by a screw plug - 1 - with sealing ring - 2 -.



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Fig. 59: Removing Wiring Harness For Engine Oil Temperature Sensor G8 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Furthermore, the wiring harness for engine oil temperature sensor G8 is removed as follows:

Remove bolts - arrows - and remove retainer - 1 - for differential motor connector.

Pivot 10-pin connector out of retainer - 2 -.

Fig. 60: Identifying Engine Oil Temperature Sensor Wiring Harness & 10-Pin Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

The wires, pins - 1 - and - 2 - of 10-pin connector must be removed using appropriate ejection tool from wiring harness repair kit VAS 1978.

Remove wiring harness - 3 - for engine oil temperature sensor.

Close off wire openings of terminals - 1 - and - 2 - in 10-pin connector .

Input shaft seal, replacing



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Fig. 61: Identifying Special Tools - Input Shaft Seal, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.


Puller T10055

Adapter T10055/2

Thrust plate T10184

Sealing grease G 052 128 A1

Sheet metal screw approx. 4 mm diameter

Removing

Remove transfer case --> Transfer case, removing.



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Fig. 62: Screwing Sheet Metal Screw Into Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.

To pull out seal, screw a sheet metal screw of approx. 4 mm diameter into seal - arrow -.

Thread in sheet metal screw in so that it jams between seal lip and metal ledge of sealing ring.

Do not screw in sheet metal screw too far to avoid damaging bearing behind it.

Pull out seal using puller T10055.

Installing



Drive new seal in as far as stop; be sure not to distort seal.

Install transfer case --> Transfer case, installing.


Output flange oil seal for front driveshaft, replacing (transfer case installed)



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Fig. 64: Identifying Special Tools - Output Flange Oil Seal For Front Driveshaft, Replacing (Transfer Case Installed) Courtesy of VOLKSWAGEN UNITED STATES, INC.


Slide hammer VW 771


Handle-Hold Dr. Shaft Flange 3145


Thrust plate T10185

Socket T10204


Loctite 648



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2 Bolts M10 x 25

Removing

Remove front driveshaft --> Front driveshaft, removing and installing.

Fig. 65: Securing Handle-Hold Dr. Shaft Flange 3145 With Bolts To Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure Handle-Hold Dr. Shaft Flange 3145 with 2 bolts M10 x 25 to output flange - arrows -.

Unscrew nut for output flange.

Remove output flange.

Pull out sealing ring using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37.

Clean threads of nut.

Installing





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Insert output flange.

Fig. 67: Moistening New O-Ring With Gear Oil And Insert Courtesy of VOLKSWAGEN UNITED STATES, INC.

Moisten new O-ring - arrow - with gear oil and insert.

Coat threads of new nut with locking fluid Loctite 648 .

Fig. 68: Tightening New Nut For Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten new nut for output flange to torque specification.



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Fig. 69: Securing Nut At Intended Points Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure nut at intended points - arrows - (e.g., using a drift).

The illustration shows securing the nut on output flange/rear driveshaft.

Install front driveshaft --> Front driveshaft, removing and installing.


Output flange oil seal for rear driveshaft, replacing (transfer case installed)

Tightening torque Nut for output flange on output shaft

Always replace nuts

130 Nm



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Fig. 70: Identifying Special Tools - Output Flange Oil Seal For Rear Driveshaft, Replacing (Transfer Case Installed) Courtesy of VOLKSWAGEN UNITED STATES, INC.


Slide hammer VW 771


Handle-Hold Dr. Shaft Flange 3145


Thrust plate T10185

Socket T10204


Loctite 648



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2 Bolts M10 x 25

Removing


Fig. 71: Unscrewing Nut For Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unscrew nut for output flange.

A - Bolts M10 x 30 with nuts

Remove output flange.

Fig. 72: Pulling Out Sealing Ring Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Clean threads of nut.



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Installing

Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.


Drive new seal in as far as the stop; be sure not to distort seal.

Insert output flange.

Fig. 74: Moistening New O-Ring With Gear Oil And Insert Courtesy of VOLKSWAGEN UNITED STATES, INC.

Moisten new O-ring - arrow - with gear oil and insert.

The figure shows the O-ring on output flange/front driveshaft.

Coat threads of new nut with locking fluid Loctite 648.



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Fig. 75: Unscrewing/Tightening Nut For Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten new nut for output flange to torque specification.

Fig. 76: Securing Nut At Intended Points Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure nut at intended points - arrows - (e.g., with a drift).



DIFFERENTIAL MOTOR V253 , REMOVING AND INSTALLING

Differential motor V253 , removing and installing


Tightening torque Nut for output flange on output shaft

Always replace nut

130 Nm



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Differential motor V253 , removing

If Differential Motor V253 is replaced, observe the following:

The new Differential Motor is set to a specified position.

To make installation easier, set this position on differential as well, if possible:

Fig. 78: Rotating Transfer Case Operating Unit E473 To "LOW" Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

To do this, switch ignition on.

Rotate Transfer Case Operating Unit E473 to "LOW" position - arrow -.



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Then switch ignition off.

If previous Differential Motor will be reinstalled, Transfer Case Operating Unit E473 does not need to be set to the "LOW" position.

Continued for all

If shield is installed over differential motor , remove it.

Fig. 79: Installing Bracket & Connecting Connectors Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate connectors - A - , - B - and - C -.

Remove bracket - D - - arrows -.

Fig. 80: Removing Bolts And Differential Motor From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.



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Remove bolts - arrows - and remove differential motor from transfer case.

Differential motor V253 , installing

If a new Differential Motor is installed, observe the following:

(Fig. 1)

Fig. 81: Identifying Transfer Case Operating Unit E473 Is In "LOW" Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

The Transfer Case Operating Unit E473 is in "LOW" position.

Shaft with interrupted tooth pattern - 1 - must be in - a - position.

" a = approx. 10° "

Transfer Case Operating Unit E473 was already turned to "LOW" position with ignition on.

Transfer Case Operating Unit setting --> (Fig. 1)

Transfer Case Operating Unit E473 was not turned to "LOW" position.

Transfer Case Operating Unit setting --> (Fig. 2)



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If necessary, set the interrupted tooth pattern - 1 - on shaft of differential motor to position shown in the illustration (e.g. using a screwdriver).

(Fig. 2)

Fig. 82: Identifying Transfer Case Operating Unit E473 Is Not In "LOW" Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

The Transfer Case Operating Unit E473 is not in "LOW" position.

Shaft with interrupted tooth pattern - 1 - must be in - a - position.

" a = approx. 60° "

If necessary, set the interrupted tooth pattern - 1 - on shaft of differential motor to the position shown in the illustration (e.g. using a screwdriver).

Continued for all

Make sure that O-ring that seals on transfer case makes contact in base of groove at the differential motor.

Set differential motor on alignment sleeves - 2 - of transfer case.

Ensure that the interrupted teeth on differential motor - arrow A - and on selector shaft/transfer case - arrow B - are aligned.



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Fig. 83: Removing/Installing Bolts And Differential Motor From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert bolts - arrows - for differential motor and fasten.

Fig. 84: Installing Bracket & Connecting Connectors Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install bracket - D - - arrows -.

Connect connectors - A - , - B - and - C -.

If shield was fitted over differential motor , install it.


Tightening torque Differential motor to transfer case 27 NmBracket for transfer case 14 Nm



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39 FINAL DRIVE, DRIVESHAFTS

DRIVESHAFTS, REMOVING AND INSTALLING

Assembly overview

Front driveshaft, removing and installing --> Front driveshaft, removing and installing.

Rear driveshaft, removing and installing --> Rear driveshaft, removing and installing.

No repairs may be performed on the driveshafts.

Do not flex rear driveshaft; store and transport extended.

Store rear driveshaft with bracket facing upward.

Before removing, mark the positions of all parts in relation to each other. Re-install in the same position otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises.

If front or rear driveshaft is disconnected only from transfer case or only from its respective final drive, it must be tied up or supported.

In customer complaints arise (noises, vibration) regarding the front or rear driveshaft, turn respective driveshaft on the final drive the distance of one bolt hole before bolting on again. This procedure can be repeated 5 times on the final drives and twice on back of transfer case.



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Fig. 85: Driveshafts Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Front final drive

Colored markings on driveshaft flange and on front driveshaft must line up.

2 - Lock plate

3 - Bolt, 30 Nm plus an additional 90° 1 /4 turn

Always replace

4 - Front driveshaft

Installation position: Colored spot on front driveshaft must line up with colored spot on front final drive



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5 - Transfer case

6 - Nut

Always replace

7 - Flexible disc

Removing and installing --> Flexible disc, removing and installing

8 - Washer

9 - Bolt, 75 Nm

10 - Rear driveshaft

Installation position: Colored spot on rear driveshaft must line up with colored spot on rear final drive

To avoid damaging boot in vicinity of center bearing - arrow - , rear driveshaft may only be flexed slightly

11 - Multi-point socket head bolt, 30 Nm plus an additional 90° 1 /4 turn

Always replace

12 - Lock plate

13 - Rear final drive

14 - Bracket

For center bearing

15 - Bolt, 20 Nm

On bracket for rear driveshaft

To adjust driveshaft center bearing free of tension, loosen and tighten --> Rear driveshaft center bearing, installing stress-free

16 - Bolt, 60 Nm

Bracket to body

17 - Bolt

18 - Hex nut, 75 Nm



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Always replace

Front driveshaft, removing and installing

Fig. 86: Identifying Special Tools - Front Driveshaft, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.




Engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2

Brake pedal loading device V.A.G 1869/2

A twin-post vehicle hoist should be used when working on the front driveshaft.



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If droning noises occur when driving, unbolt front driveshaft from flange at front final drive, rotate one hole relative to flange and bolt on again.

If droning noises are still audible, the front driveshaft can be rotated one hole relative to flange a total of 5 times.

Removing

For vehicles with automatic transmission, select position "N" with selector lever.

Insert brake pedal depressor V.A.G 1869/2.

Raise vehicle.

Remove sound insulation on bottom of transmission.

If an underbody impact guard is located beneath the driveshaft, remove it --> 50 - BODY - FRONT .

Fig. 87: Identifying Mark On Driveshaft Flange & Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check whether there is a colored marking on front driveshaft and at driveshaft flange at front final drive.

If this marking is not present, then mark in color the position of driveshaft flange - arrow A - to front final drive - arrow B -.



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Fig. 88: Removing Lower Three Bolts From Front Driveshaft At Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove lower three bolts from front driveshaft at front final drive - arrows A -.

Fig. 89: Removing Lower Three Bolts From Front Driveshaft At Output Flange Of Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove lower three bolts from front driveshaft at output flange of transfer case - arrows B -.

Lower vehicle.

Remove brake pedal depressor V.A.G 1869/2.

Raise vehicle.

Rotate both front wheels in same direction at same time so that the front driveshaft rotates 1 /2 turn

(180°).

Lower vehicle.


Raise vehicle.

Remove remaining three bolts from front driveshaft at front final drive and at transfer case.



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Fig. 90: Placing Engine/Transmission Jack V.A.G 1383 A With Universal Adapter 1359/2 And Block Of Wood Under Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove transmission carrier as follows:

Place engine/transmission jack V.A.G 1383 A with universal adapter 1359/2 and a block of wood - A - under transfer case.

Do not loosen bolts - arrows - yet.


Unbolt transmission carrier - A - from structure - arrows -.



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Remove bolt for transmission carrier from transfer case console - arrows -.

Remove front driveshaft.

If the front driveshaft cannot be removed, lower the engine/transmission assembly slightly. When doing this, the engine must not come to rest against the bulkhead.

Installing

Installation is in reverse order of removal. Note the following:

Fig. 93: Identifying Mark On Driveshaft Flange & Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Always replace bolts for front driveshaft.

Markings - arrow A - and - arrow B - must line up as much as possible.



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Install transmission carrier as follows:

Use new bolts.

First tighten the transmission carrier to the transfer case console - arrows - to tightening torque.


Then, tighten the transmission carrier - A - to the body - arrows - to tightening torque --> Tightening torques.

Insert bolts for front driveshaft and tighten to tightening torque --> Tightening torques

If an underbody impact guard is located beneath the driveshaft, install it --> 50 - BODY - FRONT .

Tightening torques Console to transmission carrier


50 Nm plus an additional 90° 1 /4 turn

Transmission carrier to structure 50 Nm plus an additional 90° 1 /4 turn



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Rear driveshaft, removing and installing

Fig. 96: Identifying Special Tools - Rear Driveshaft, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.



Always replace bolts Front driveshaft to front final drive flange



Front driveshaft to transfer case flange





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A twin-post vehicle hoist should be used when working on the rear driveshaft.


If droning noises occur when driving, unbolt rear driveshaft from flange at rear final drive, rotate one hole relative to flange and bolt on again.

If droning noises are still audible, rear driveshaft can be rotated one hole relative to flange a total of 5 times at rear final drive and a total of 2 times at transfer case.

Do not flex rear driveshaft; store only extended with center bearing bracket facing upward.

Removing

For vehicles with automatic transmission, select position "N" with selector lever.


Raise vehicle.

Remove rear part of exhaust system -->






.

If an underbody impact guard is located beneath the driveshaft, remove it --> 50 - BODY - FRONT .



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Fig. 97: Identifying Mark On Driveshaft Flange & Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check whether there is a colored marking on rear driveshaft and on driveshaft flange at rear final drive.

If marking is not present, mark in color position of driveshaft flange - arrow A - to rear final drive - arrow B -.

Fig. 98: Marking Position Of Rear Driveshaft To Transfer Case Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark position of rear driveshaft to transfer case output flange - arrow -.



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Fig. 99: Removing Lower Bolts For Rear Driveshaft At Rear Final DriveCourtesy of VOLKSWAGEN UNITED STATES, INC.

Remove lower 3 bolts for rear driveshaft at rear final drive.

Lower vehicle.

Remove brake pedal depressor V.A.G 1869/2.

Raise vehicle.

Rotate both rear wheels in same direction at the same time so that the rear driveshaft rotates 1 /2 turn

(180°).

Lower vehicle.


Raise vehicle.

Remove remaining 3 bolts for rear driveshaft at rear final drive.

Fig. 100: Removing Bolts From Rear Driveshaft At Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - from rear driveshaft at transfer case. For this, counterhold nuts with an open end wrench.

Place engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2 under subframe/rear axle.



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Fig. 101: Removing/Installing Both Front Bolts On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.

Support subframe with a wooden block --> Fig. 102.

Remove both front bolts - arrows - on subframe.

Fig. 102: Lowering Subframe Using Engine/Transmission Jack V.A.G 1383 A Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lower subframe using engine/transmission jack V.A.G 1383 A by dimension - a - = 50 mm.

1 - Wooden support

To avoid damaging rear driveshaft, have a second technician assist in removing rear driveshaft.



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Fig. 103: Loosening Bolts For Center Bearing Bracket & Unbolting Center Bearing Bracket From BodyCourtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen bolts - arrows B - for center bearing bracket by approx. 2 turns.

Unbolt center bearing bracket from body - arrows A -.

Fig. 104: Pressing Rear Driveshaft Off Of Rear Final Drive And Pivot It Over Final Drive Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press rear driveshaft - 1 - off of rear final drive - 2 - and pivot it over final drive flange.

Carefully pull rear driveshaft off from alignment sleeves of output flange/transfer case.

Remove rear driveshaft.

Set aside rear driveshaft with center bearing bracket facing upward.

Installing




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Always replace bolts for rear driveshaft.

Markings - arrow A - and - arrow B - must line up as much as possible.

Fig. 106: Identifying Seal In Rear Driveshaft Flange At Flange/Transfer Case Must Not Be Damaged When Removing/Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Seal - arrow - in rear driveshaft flange at flange/transfer case must not be damaged when removing and installing.

Replace rear driveshaft if damaged.

Do not tip rear driveshaft; push horizontally onto guide shaft.

After loosening a rear driveshaft flange, install center bearing so that it is free of stress --> Rear driveshaft center bearing, installing stress-free.



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Fig. 107: Removing/Installing Both Front Bolts On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install and fasten bolts - arrows - at subframe --> 42 - REAR SUSPENSION

After installing rear driveshaft, install center bearing so that it is free of stress --> Rear driveshaft center bearing, installing stress-free.

Install rear part of exhaust system -->






.

Insert bolts for rear driveshaft and tighten to specified torque.

If an underbody impact guard is located beneath the driveshaft, install it --> 50 - BODY - FRONT .

Rear driveshaft center bearing, installing stress-free

Tightening torques Rear driveshaft to rear final drive flange



Rear driveshaft to flexible disc


75 Nm

Center bearing bracket to body 60 Nm



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If necessary, remove rear part of exhaust system -->






.


Remove bolts - arrows B -.

Loosen bolts - arrows A - several turns.

Fig. 109: Aligning Center Bearing Bracket Centrally To Lateral Stops On Body Courtesy of VOLKSWAGEN UNITED STATES, INC.



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Align center bearing bracket centrally to lateral stops - arrows - on body.

Fix center bearing bracket in place by fastening the two bolts - A -.

Check if threaded holes of center bearing - B - are lined up with slots of bracket.

For slight deviations:

Move center bearing bracket laterally until the threaded holes and slots line up.

When moving bracket, make sure that the center bearing does not touch the body (driveshaft tunnel).

For larger deviations or if clearance between center bearing and body is minimal:


Loosen bolts - arrows - for transmission carrier by approx. 3 turns.

Move transmission laterally until threaded holes of center bearing and slots of center bearing bracket line up.

When moving transmission, make sure that the center bearing does not touch body (driveshaft tunnel).

Replace individual bolts - arrows - , in succession, for transmission carrier and tighten them to tightening torque.



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Install bolts - arrows B - and fasten bolts - arrows A - and - arrows B -.

If removed earlier, install rear part of exhaust system -->






.

Flexible disc, removing and installing


Torque specifications Center bearing bracket to body 60 NmRear driveshaft center bearing to bracket 20 NmTransmission carrier to structure


50 Nm plus an additional 90° 1 /4



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Fig. 113: Brake Pedal Depressor V.A.G 1869/2 Courtesy of VOLKSWAGEN UNITED STATES, INC.


A twin-post vehicle hoist should be used when working on the rear driveshaft.


Do not flex rear driveshaft; store only extended with center bearing bracket facing upward.

Removing

For vehicles with automatic transmission, select position "N" with the selector lever.


Raise vehicle.



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.


Fig. 114: Unbolting Flexible Disc From Rear Driveshaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt flexible disc from rear driveshaft - arrows -.

Installing




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Fig. 115: Identifying Seal In Rear Driveshaft Flange At Flange/Transfer Case Must Not Be Damaged When Removing/Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Seal - arrow - in rear driveshaft flange at flange/transfer case must not be damaged when removing and installing.

Replace rear driveshaft if damaged.

Do not tip rear driveshaft; push horizontally onto guide shaft.


After installing rear driveshaft, install center bearing so that it is free of stress --> Rear driveshaft center bearing, installing stress-free.







.

Tightening torque Flexible disc to transfer case flange

Always replace nut, build torque at the bolt while counterholding the nut

75 Nm



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39F FINAL DRIVE, FRONT DIFFERENTIAL

GEAR OIL IN FRONT FINAL DRIVE, CHECKING







Oil level is correct when the front final drive is filled up to lower edge of oil filler hole.

Fasten bolt - arrow - with new seal.

When initially filling front final drive



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Remove bolt - arrow -.



FRONT FINAL DRIVE, REMOVING AND INSTALLING

Front final drive, removing and installing

Fig. 118: Identifying Special Tools - Front Final Drive, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.


Tightening torque Oil filler plug to front final drive 35 Nm



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Tensioner hooks VW 552

Spindle 10 - 222 A/11




Socket insert T10099/1

Front final drive, removing

Loosen wheel bolts.

Raise vehicle.

Remove front wheels.

Remove left front and right wheel housing liners --> 68 - INTERIOR EQUIPMENT .

Fig. 119: Hooking In Tensioner Hooks VW552 On Both Vehicles Sides In Upper Opening Of Wheel Housing And In Upper Control Arm Courtesy of VOLKSWAGEN UNITED STATES, INC.

If equipped with air spring struts, the air line connection - 1 - must be loosened and allow air to escape. Then, tighten connection to specified torque --> 40 - FRONT SUSPENSION .

Hook tensioner hooks VW 552 onto each side of vehicle in upper openings of wheel housing - arrow A - and in upper control arms - arrow B -.

Pretension control arm slightly so that ball joint pin of control arm will not be damaged.

Remove sound insulation below engine/transmission.

If an underbody impact guard is located beneath the front final drive, remove it --> 50 - BODY - FRONT .

Remove sound insulation retainer.



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Fig. 120: Removing/Installing Shield From Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove shield from front final drive - arrows -.

Fig. 121: Removing Lower Three Bolts From Front Driveshaft At Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect driveshaft from front final drive - arrows A - and tie up --> Front driveshaft, removing and installing.

Unbolt left and right drive axles. To loosen bolts, use socket insert T10099/1 if necessary.



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Fig. 122: Identifying Universal Joint Bolt And Heat ShieldCourtesy of VOLKSWAGEN UNITED STATES, INC.

If equipped, remove shield - A - from steering gear (2 bolts).

Remove bolt - B - for universal joint on steering gear and pull universal joint from steering gear.

Fig. 123: Identifying Coolant Pipes, Nut & Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

If equipped, remove coolant pipes - 1 - from left longitudinal member. When doing this, remove nut - A - and bracket - arrow B -.

Fig. 124: Hooking Spindles 10 - 222 A/11 In Eyelets Of Engine Carrier On Left/Right Vehicle Sides Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hook spindles 10 - 222 A/11 in eyes - arrow - of subframe on left and right sides of vehicle.



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Fig. 125: Setting Wooden Block Into Hanger Of Each Spindle 10 - 222 A/11 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set a wooden block - A - approx. 300 mm long into the hanger of each spindle 10 - 222 A/11.

Hangers must face toward the rear.

Tighten winged nuts of spindles , ensuring that wooden blocks lie against subframe - B -.

Place insert from a trolley jack into engine/transmission jack V.A.G 1383 A.

Fig. 126: Placing Engine/Transmission Jack V.A.G 1383 A Under Engine Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place engine/transmission jack V.A.G 1383 A under subframe and lightly press against it.

A - Wooden support

Remove one of the subframe mounting bolts - arrows -.



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Fig. 127: Checking Inner Contour Of Sleeve In Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check inner contour of sleeve - arrow - in bonded rubber bushing.

Remove mounting bolts for subframe from body - arrows - in Fig. 128.

Fig. 128: Removing/Installing Coupling Rods On Left/Right From Stabilizer Bar Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect left and right - 1 - coupling rods from stabilizer bar.

Remove threaded connection from air spring strut or suspension strut to lower control arm. The subframe must be lowered via the spindles 10 - 222 A/11 by approx. 50 mm direction of - arrow - to remove bolt - 2 -.

Inner contour of sleeve Rectangular Subframe cannot be secured.

Mark position of subframe on body using a felt tip pen.

Round Secure subframe before removal --> 40 - FRONT SUSPENSION



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Use bolts - 2 - with additional washers, or bolts M14 x 1.5 approx. 90 mm long, to secure subframe to body on left and right - 3 -.

Remove engine/transmission jack V.A.G 1383 A from under subframe.

Fig. 129: Placing Engine/Transmission Jack V.A.G 1383 A With Universal Transmission Adapter 1359/2 Under Subframe And Lightly Press Against It Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2 under subframe and lightly press against it. When doing this, place wooden block - A - underneath subframe and - B - under front final drive.

Secure subframe with belt from universal transmission adapter V.A.G 1359/2.

Remove spindles 10 - 222 A/11 from subframe.

Fig. 130: Pulling/Pushing Breather Line With Connecting Nipple Carefully Off Of Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull breather line - A - with connecting nipple - arrow - carefully off of front final drive.



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Fig. 131: Measuring Dimension Between Body And Fastening Surface Of Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully lower subframe with front final drive to dimension - a - , approx 200 mm.

Measure dimension - a - between body and fastening surface of subframe.

Fig. 132: Removing/Installing Bolts With Nuts For Front Final Drive On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts with nuts - 1 - through - 3 - for front final drive - A - on subframe - B -.

A second technician is required to remove front final drive.



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Fig. 133: Removing Front Final Drive Rearward Between Subframe And Engine/Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove front final drive - 1 - rearward between subframe and engine/transmission as follows:

Tie up left drive axle.

Have second technician remove front final drive from supports in subframe.

Guide right drive axle out of flange shaft.

Raise front final drive over steering gear and guide out toward rear.

Front final drive, installing


Always replace bolts for front driveshaft.

A second technician is required to insert front final drive into subframe supports.



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Fig. 134: Removing/Installing Bolts With Nuts For Front Final Drive On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install bolts with nuts - 1 - through - 3 - for front final drive - A - on subframe - B - --> 40 - FRONT SUSPENSION .

Raise subframe using transmission jack.

Fig. 135: Pulling/Pushing Breather Line With Connecting Nipple Carefully Off Of Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push breather line - A - with connecting nipple - arrow - carefully into front final drive. When doing so, connecting nipple must be stand vertical and be inserted between raised areas of the housing.



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Fig. 136: Hooking Spindles 10 - 222 A/11 In Eyelets Of Engine Carrier On Left/Right Vehicle Sides Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hook spindles 10 - 222 A/11 in eyes - arrow - of subframe on left and right sides of vehicle.

Fig. 137: Setting Wooden Block Into Hanger Of Each Spindle 10 - 222 A/11 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set a wooden block approx. 300 mm long into hanger of each spindle 10 - 222 A/11.

Hangers must face rearward.

Tighten winged nuts of spindles , ensuring that the wooden blocks lie against subframe - B -.

Remove engine/transmission jack V.A.G 1383 A from under subframe.

Place insert from a trolley jack into engine/transmission jack V.A.G 1383 A.



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Place engine/transmission jack V.A.G 1383 A under subframe and lightly press against it.

A - Wooden support

Fig. 139: Removing/Installing Coupling Rods On Left/Right From Stabilizer Bar Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove temporarily installed bolts - 3 - for subframe on left and right.

Install bolts - 2 - for air spring strut or suspension strut on lower control arm.

Fasten coupling rods on left and right - 1 - to stabilizer --> 40 - FRONT SUSPENSION .



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Fig. 140: Checking Inner Contour Of Sleeve In Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before bolting on subframe, check inner contour of bonded rubber bushing sleeve in subframe - arrow -.

Bolt on subframe - arrows - --> 40 - FRONT SUSPENSION


If an axle alignment was performed, the bolts must be replaced --> 40 - FRONT SUSPENSION

Tighten bolts to tightening torque --> 48 - STEERING .

Remove spindles 10 - 222 A/11 from subframe.

Inner contour of sleeve Rectangular Vehicle must be aligned after assembling the

subframe --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT

Round If steering wheel is crooked, a vehicle alignment must be performed --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT .



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Fig. 142: Identifying Universal Joint Bolt And Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install universal joint on steering gear and tighten bolt - B - to tightening torque --> 40 - FRONT SUSPENSION

If equipped, install shield - A - to steering gear --> 40 - FRONT SUSPENSION .

Fig. 143: Identifying Coolant Pipes, Nut & Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

If equipped, install coolant pipes - 1 - on left longitudinal member. When doing this, fasten nut - arrow A- and bracket - arrow B - --> 82 AUXILIARY HEATER .

Connect front driveshaft --> Front driveshaft, removing and installing.



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Fig. 144: Removing/Installing Shield From Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install shield - arrows - and tighten bolts to 10 Nm.

Install drive axles to flange shafts --> 40 - FRONT SUSPENSION .

Remove tensioner hooks VW 552.

Install left front and right wheel housing liners --> 66 - EXTERIOR EQUIPMENT .

Check gear oil in front final drive --> Gear oil in front final drive, checking.

If an underbody impact guard is located beneath the front final drive, install it --> 50 - BODY - FRONT .

Install front wheels --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT .

After installation, a vehicle alignment must be performed --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT .

Breather line for front final drive, routing

Fig. 145: Breather Line For Front Final Drive, Routing Courtesy of VOLKSWAGEN UNITED STATES, INC.

The breather line - 1 - runs from front final drive - 3 - , along behind right engine mount - 4 - and then is clipped to the air filter - 2 -.



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SEALS AT FRONT FINAL DRIVE, REPLACING

Left flange shaft oil seal, replacing

Fig. 146: Identifying Special Tools - Left Flange Shaft Oil Seal, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.


Punch VW 412

Thrust plate VW 432

Support channels VW 457

Slide hammer VW 771

Seal installer 2003/3



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Alignment fixture 3301



Fig. 147: Identifying Kukko Tools Courtesy of VOLKSWAGEN UNITED STATES, INC.


Fig. 148: Thrust Plate T10260 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thrust plate T10260

Removing

Remove front final drive --> Front final drive, removing.



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Fig. 149: Securing Slide Hammer VW 771 To Left Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure slide hammer VW 771 to left flange shaft.

Pull out left flange shaft.

Fig. 150: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 771/37.

Installing



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Fig. 151: Driving In New Oil Seal Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive in new oil seal up to stop.


Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary.

Fig. 152: Removing Old Circlip From Groove In Flange Shaft Using Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove old circlip - A - from groove in flange shaft using pliers.

B - Vise jaw protectors

Insert new circlip in groove of flange shaft, being careful not to over-stretch circlip.

Drive in flange shaft using a plastic head hammer.

Install front final drive --> Front final drive, installing.


Dust cap for flange shaft, replacing



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Fig. 153: Pressing Off Dust Cap From Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press off dust cap - B - from flange shaft.


Fig. 154: Pressing Dust Cap Onto Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press dust cap - A - onto flange shaft.

Set sleeve 3301/3 in place with recess - arrow - facing dust cap - A -.

Right flange shaft seal, replacing




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Fig. 155: Slide Hammer-Multi-Purpose Tool Set VW 771 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide hammer VW 771



Thrust plate T10259


Removing




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Fig. 157: Securing Slide Hammer VW 771 To Right Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure slide hammer VW 771 to right flange shaft.

Pull out right drive flange.

Fig. 158: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 771/37.

Installing



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Seal for driveshaft flange on front final drive, replacing (final drive removed)



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Fig. 161: Identifying Special Tools - Seal For Driveshaft Flange On Front Final Drive, Replacing (Final Drive Removed) (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.



Punch VW 407

Punch VW 412

Slide hammer VW 771

Pulling hook 771/37

Sleeve 40 - 20



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Fig. 162: Identifying Special Tools - Seal For Driveshaft Flange On Front Final Drive, Replacing (Final Drive Removed) (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.


Counter holder 3435


Friction meter VAS 6222

Thrust plate T10183



Loctite 648

2 Bolts M10 x 25



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Removing


Lay front final drive on a workbench.

Fig. 163: Measure Friction Torque Using Friction Meter VAS 6222 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before loosening drive pinion nut, measure friction torque.

Note friction torque value. After seal is replaced, friction torque must be restored to this value.

Use friction meter VAS 6222.

Fig. 164: Removing Hex Nut For Drive Shaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove hex nut for drive shaft flange.

A - 2 Bolts M10 x 25

When loosening the nut of the driveshaft flange, counterhold using counter holder 3435 (2nd technician required).



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Fig. 165: Marking Installation Position Of Driveshaft Flange Relative To Drive Pinion Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark installation position of driveshaft flange - arrow A - relative to drive pinion - arrow B -.

Pull off driveshaft flange. If difficult to remove, use slide hammer VW 771.

Fig. 166: Pulling Out Sealing Ring Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out sealing ring.

Clean threads for nut on drive pinion.

Installing



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Before installing driveshaft flange, check dust cap for damage. Replace dust cap if necessary.

Install driveshaft flange, being aware of marking from removal .


Fig. 168: Removing Hex Nut For Drive Shaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten new nut for drive pinion until friction torque measured prior to removal is attained .

A - 2 Bolts M10 x 25

When tightening the nut of the driveshaft flange, counterhold using counter holder 3435 (2nd technician required)



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Fig. 169: Measure Friction Torque Using Friction Meter VAS 6222 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Increase tightening torque gradually, frequently measuring friction torque. The friction torque measured prior to removal must not be exceeded! Otherwise front final drive must be replaced!



Dust cap for driveshaft flange, replacing

Fig. 170: Pressing Dust Cap Off Of Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press dust cap off of driveshaft flange.




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Fig. 171: Pressing Dust Cap Onto Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press dust cap - A - onto driveshaft flange.

Installation position of dust cap: Depression on dust cap faces up toward sleeve 40 - 20.

NEEDLE BEARING FOR LEFT FLANGE SHAFT, REPLACING

Needle bearing for left flange shaft, replacing



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Fig. 172: Identifying Special Tools - Needle Bearing For Left Flange Shaft, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.


Mandrel 30 - 505

Thrust pad 30 - 506 B

- 1 - - Kukko 21/6 Internal puller

- 4 - - Kukko 22/2 Counter-support

Needle bearing, removing


Remove left flange shaft and seal --> Left flange shaft oil seal, replacing.



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Fig. 173: Pulling Out Needle Bearing For Left Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out needle bearing for left flange shaft.

A - Internal puller 37 to 46 mm, e.g. Kukko 21/6

B - Counter support, e.g. Kukko 22/2

Needle bearing, installing

Fig. 174: Driving In Needle Bearing For Left Flange Shaft Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drive in needle bearing - A - for left flange shaft up to stop.

Install left flange shaft and seal --> Left flange shaft oil seal, replacing.



BONDED RUBBER BUSHING AT FRONT FINAL DRIVE, REPLACING

Bonded rubber bushing at front final drive, replacing



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Fig. 175: Identifying Special Tools - Bonded Rubber Bushing At Front Final Drive, Replacing (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.


Thrust plate VW 442

Sleeve 30 - 14






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Fig. 176: Identifying Special Tools - Bonded Rubber Bushing At Front Final Drive, Replacing (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.


Thrust pad VW 512

Thrust plate VW 554


Alignment fixture T10030

Bonded rubber bushing, installation position

Bonded rubber bushings with 2 recesses



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Fig. 177: Bonded Rubber Bushings With 2 Recesses Courtesy of VOLKSWAGEN UNITED STATES, INC.

The recesses in the bushing must be vertical relative to final drive - arrows -.



The smaller recesses - arrows - and smaller holes - A - of bushings must be vertical relative to final drive.

Bonded rubber bushing at driveshaft flange, pulling out and in



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Fig. 179: Pulling Out Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out bonded rubber bushing.

It is important to grease spindle 3346/2 with Molybdenum grease before using.

Pull in bonded rubber bushing - A -.

Fig. 180: Pulling In Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull in bonded rubber bushing - A - only so far until dimension - a - is achieved.



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Fig. 181: Installation Depth For Bonded Rubber Bushing At Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installation depth for bonded rubber bushing at driveshaft flange.

Dimension - a - = 47.5 mm

Bonded rubber bushing at front housing, pulling out and in




To pull out, place special tool 3346/1 with flat shoulder facing toward bonded rubber bushing onto spindle 3346/2.



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Fig. 183: Pulling In Bonded Rubber Bushing Until It Is Centered In Front Final Drive Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull in bonded rubber bushing - A - until it is centered in front final drive housing.

Bonded rubber bushing at extension tube for left flange shaft, pulling out and in

Removing and installing bonded rubber bushing on extension tube for left flange shaft is identical to the procedure for removing and installing bonded rubber bushing on rear final drive --> Bonded rubber bushing on rear final drive, replacing.

39R FINAL DRIVE, REAR DIFFERENTIAL

ELECTRICAL/ELECTRONIC COMPONENTS AND LOCATIONS FOR REAR FINAL DRIVE DIFFERENTIAL LOCK

Electrical/electronic components and locations for rear final drive differential lock



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Fig. 184: Electrical/Electronic Components And Locations For Rear Final Drive Differential Lock Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Differential lock control module J647

Location --> Location of Differential lock control module J647

Removing and installing --> Differential lock control module J647 , removing and installing

2 - Transfer case operating unit E473

Location --> Location of transfer case operating unit E473

Removing and installing --> 68 - INTERIOR EQUIPMENT .

3 - Differential lock motor V304

Location --> Location of Differential lock motor V304



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Removing and installing --> Differential lock motor V304 , removing and installing

The following components are integrated into differential lock motor V304 :

Motor temperature sensor G407

Differential lock position sensor 1 G460

Differential lock position sensor 2 G461

Brake for locking motor

4 - Data Link Connector (DLC)

Location --> Data Link Connector (DLC)

5 - Multi-function display in instrument cluster

Indicates condition and information about differential lock in rear final drive

Location of Differential lock control module J647

Fig. 185: Location Of Differential Lock Control Module J647 Courtesy of VOLKSWAGEN UNITED STATES, INC.

The differential lock control module J647 is located behind the side trim on the left rear wheel housing - arrow -.

Differential lock control module J647 , removing and installing --> Differential lock control module J647 , removing and installing.

Location of transfer case operating unit E473



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Fig. 186: Location Of Transfer Case Operating Unit E473 Courtesy of VOLKSWAGEN UNITED STATES, INC.

The transfer case operating unit E473 - 1 - is located in the shift cover - 2 - of the center console.

Transfer case operating unit E473 , removing and installing --> 70 - INTERIOR TRIM .

Location of Differential lock motor V304

Fig. 187: Setting Differential Lock Motor V304 With Holder For Connector Into Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.

The differential lock motor V304 - A - is located in front of the left flange shaft on the rear final drive.

Differential lock motor V304 , removing and installing --> Differential lock motor V304 , removing and installing

Data Link Connector (DLC)



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Fig. 188: Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.

The Data Link Connector (DLC) is located in the cover of the drivers side footwell.

Differential lock control module J647 , removing and installing

Removing

Check whether a coded radio is installed. If so, obtain radio anti-theft coding.

Switch ignition and all electrical consumers off, and remove ignition key.

Disconnect Ground (GND) terminal connector from battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Remove left rear side trim --> 72 - SEAT - FRAMES .

Vehicles with Four-zone Climatronic

Move rear auxiliary heater and air conditioner unit into service position --> 87 AIR CONDITIONING .

Continued for all vehicles

Fig. 189: Identifying Differential Lock Control Module J647 Connector, Bolt & Differential Lock Control Module J647



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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate connector - 1 - at differential lock control module J647.

Remove bolt - 2 -.

Unclip holder with differential lock control module J647 - 3 - from structure - arrows - and remove holder with differential lock control module J647.

Installing


Fig. 190: Identifying Differential Lock Control Module J647 Connector, Bolt & Differential Lock Control Module J647 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clip holder with differential lock control module J647 - 3 - into structure - arrows -.

Tighten bolt - 2 - to 2 Nm.

Connect Ground (GND) terminal connector to battery and perform work sequences after connecting battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

GEAR OIL IN REAR FINAL DRIVE, CHECKING

Gear oil in rear final drive, checking





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The oil level is correct when the rear final drive is filled to the lower edge of the filler hole.


When initially filling rear final drive

Remove bolt - arrow -.



Tightening torque Oil filler plug to rear final drive 35 Nm



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REAR FINAL DRIVE, REMOVING AND INSTALLING

Rear final drive, removing and installing

Fig. 193: Identifying Special Tools - Rear Final Drive, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.





Rear final drive, removing

Raise vehicle.



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If an underbody impact guard is located beneath the rear final drive, remove it --> 50 - BODY - FRONT .







.


Check whether there is a marking (colored marking) on rear driveshaft and on driveshaft flange at rear final drive.

If no markings can be found, mark in color the position of the driveshaft flange - arrow A - to rear final drive - arrow B -.



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Fig. 195: Disconnecting Rear Driveshaft From Rear Final Drive And Tie Up Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect rear driveshaft from rear final drive and tie up - arrow - --> Rear driveshaft, removing and installing.

If equipped, remove differential lock motor V304 --> Differential lock motor V304 , removing.

Fig. 196: Disconnecting Left/Right Drive Shafts And Tie-Up Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect left - 2 - and right - 1 - drive shafts and tie-up.

Place engine/transmission jack V.A.G 1383 A with universal transmission adapter V.A.G 1359/2 under rear final drive.

Remove bolts and nuts for rear final drive at subframe - arrows -.



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Fig. 197: Tipping Up Rear Final Drive At Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tip up rear final drive at driveshaft flange - A -.

Lower rear final drive slightly and pull breather line off connection nipple.

Lower rear final drive.

Rear final drive, installing


Always replace bolts for rear driveshaft.


To prevent imbalance, the rear driveshaft flange - arrow A - and rear final drive - arrow B - must be installed so that the colored markings from the factory or those subsequently made are in alignment.



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Fig. 199: Fastening Rear Final Drive To Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten rear final drive to subframe - arrows - --> 42 - REAR SUSPENSION .

Fasten right - 1 - and left - 2 - driveshafts at flange shafts --> 42 - REAR SUSPENSION .

If equipped, install the differential lock motor V304 --> Differential lock motor V304 , installing.

Connect rear driveshaft --> Rear driveshaft, removing and installing.

Install center bearing for driveshaft, so that it is free of stress --> Rear driveshaft center bearing, installing stress-free.

Check gear oil in rear final drive --> Gear oil in rear final drive, checking.

If an underbody impact guard is located beneath the rear final drive, install it --> 50 - BODY - FRONT .







.

Breather line for rear final drive, routing



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Fig. 200: Breather Line For Rear Final Drive, Routing Courtesy of VOLKSWAGEN UNITED STATES, INC.

The breather line - A - runs from the rear final drive - B - over the subframe to connection - C -.

The breather line - A - is clipped into this.

DIFFERENTIAL LOCK MOTOR V304 , REMOVING AND INSTALLING

Differential lock motor V304 , removing and installing




Differential lock motor V304 , removing

Separate two connectors at differential lock motor.



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Remove four bolts and remove differential lock motor differential lock motor - A - with holder for connector - B -.

Differential lock motor V304 , installing

Fig. 203: Replacing O-Ring On Differential Lock Motor V304 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace O-ring - arrow - on Differential lock motor V304

NOTE: Differential lock motor V304 is delivered as a replacement part with O-ring



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Set Differential lock motor V304 - A - with holder for connector - B - into rear final drive, and install and tighten four bolts.

Connect two connectors at Differential lock motor V304.

Checking gear oil in rear final drive --> Gear oil in rear final drive, checking.

SEALS AT REAR FINAL DRIVE, REPLACING

Seal for left flange shaft, replacing (vehicles without differential lock)

installed.

O-ring is secured with a protective sleeve.

Remove protective sleeve before installing Differential lock motor V304.

Tightening torque Differential lock motor V304 at rear final drive 8 Nm



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Fig. 205: Identifying Special Tools - Seal For Left Flange Shaft, Replacing (Vehicles Without Differential Lock) Courtesy of VOLKSWAGEN UNITED STATES, INC.



Punch VW 412

Slide hammer VW 771


Tube 3146





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Thrust plate T10256

Removing

Remove rear final drive --> Rear final drive, removing.






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Fig. 208: Pulling Out Seal For Flange Shaft Using VW 771/1 And VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out seal for flange shaft using VW 771/1 and VW 771/37.

Installing




Before installing the flange shaft, check the dust cap for damage. Replace dust cap if necessary.



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Install rear final drive --> Rear final drive, installing.








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Seal for left flange shaft, replacing (vehicles with differential lock)



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Fig. 213: Identifying Special Tools - Seal For Left Flange Shaft, Replacing (Vehicles With Differential Lock) Courtesy of VOLKSWAGEN UNITED STATES, INC.




Punch VW 407

Punch VW 412

Slide hammer VW 771


Sleeve 3144




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Fig. 214: Identifying Kukko Tools Courtesy of VOLKSWAGEN UNITED STATES, INC.



Thrust plate T10258

Removing




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Fig. 217: Pulling Out Seal For Flange Shaft Using VW 771/1 And VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37.

Installing



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Seal for right flange shaft, replacing (vehicles without differential lock)




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Slide hammer VW 771



Thrust plate T10181


Removing




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Fig. 225: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Installing



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Seal for right flange shaft, replacing (vehicles with differential lock)




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Slide hammer VW 771



Thrust plate T10257


Removing




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Fig. 231: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Installing



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Sealing ring for driveshaft flange on rear final drive, replacing (final drive removed)



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Fig. 234: Identifying Special Tools - Sealing Ring For Driveshaft Flange On Rear Final Drive, Replacing (Final Drive Removed) (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.



Punch VW 407

Punch VW 412

Slide hammer VW 771


Sleeve 40 - 20



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Fig. 235: Identifying Special Tools - Sealing Ring For Driveshaft Flange On Rear Final Drive, Replacing (Final Drive Removed) (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.


Handle-Hold Dr. Shaft Flange 3145 (change: expand holes to 10 mm diameter)


Friction meter VAS 6222

Thrust plate T10182



Loctite 648

2 Bolts M10 x 25



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Removing

If necessary, expand holes in Counterhold 3145 to 10 mm diameter.


Set rear final drive on a workbench.

Fig. 236: Measuring Friction Torque Courtesy of VOLKSWAGEN UNITED STATES, INC.

Before loosening drive pinion nut, measure friction torque.

Note friction torque value. After seal is replaced, friction torque must be restored to this value.

Use friction meter VAS 6222.

Fig. 237: Removing/Installing Flange/Drive Shaft Hex Nut Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove flange/drive shaft hex nut as follows:

Secure Handle-Hold Dr. Shaft Flange 3145 with 2 bolts M10 x 25 to driveshaft flange - arrows -.

When loosening the driveshaft flange nut, counterhold using Handle-Hold Dr. Shaft Flange 3145 (2nd technician required).



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Fig. 238: Marking Installation Position Of Driveshaft Flange Relative To Drive Pinion Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark installation position of driveshaft flange - arrow A - relative to drive pinion - arrow B -.

Pull off flange for driveshaft. If the task is difficult, use slide hammer VW 771.


Clean threads for nut on drive pinion.

Installing


Drive new seal in as far as the stop; be sure not to distort seal.


Before installing driveshaft flange, check dust cap for damage. Replace dust cap if necessary.

Install driveshaft flange, being aware of marking from removal .




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Fig. 240: Removing/Installing Flange/Drive Shaft Hex Nut Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten new nut for drive pinion until friction torque measured prior to removal is attained.

When tightening the nut of the driveshaft flange, counterhold using Handle-Hold Dr. Shaft Flange 3145 (2nd technician required).

Fig. 241: Measuring Friction Torque Courtesy of VOLKSWAGEN UNITED STATES, INC.

Increase tightening torque gradually, frequently measuring friction torque. The friction torque measured prior to removal must not be exceeded! Otherwise the rear final drive must be replaced!



Dust cap for driveshaft flange, replacing



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Fig. 242: Pressing Dust Cap Off Of Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press dust cap off of driveshaft flange.


Fig. 243: Pressing Dust Cap Onto Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press dust cap - A - onto driveshaft flange.

Installation position of dust cap: Depression on dust cap faces up toward sleeve 40 - 20.

BONDED RUBBER BUSHING ON REAR FINAL DRIVE, REPLACING

Bonded rubber bushing on rear final drive, replacing



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Fig. 244: Identifying Special Tools - Bonded Rubber Bushing On Rear Final Drive, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.


Thrust plate VW 442

Thrust plate VW 554

Sleeve 30 - 14




Bonded rubber bushing, installation position



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Fig. 245: Bonded Rubber Bushing, Installation Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

The recesses in the bushing must be vertical relative to final drive - arrows -.



The smaller recesses - arrows - and smaller holes - A - of bushings must be vertical relative to final drive.

Bonded rubber bushing at driveshaft flange, pulling out and in

Always grease spindle 3346/2 with Molybdenum grease before inserting



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Pull in bonded rubber bushing - A - to stop.

Fig. 248: Pulling In Bonded Rubber Bushing To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.

Rear bonded rubber bushing, pulling out and in

The process for pulling out and in the rear bonded rubber bushing at the rear final drive is identical to the process for the bonded rubber bushing at the driveshaft flange --> Bonded rubber bushing at driveshaft flange, pulling out and in.

Before pulling out a bonded rubber bushing, the corresponding flange shaft must first be removed --> Seal for left flange shaft, replacing (vehicles without differential lock).



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Documents

00 GENERAL, TECHNICAL DATAkankondemuamba.a.k.f.unblog.fr/files/2012/04/rear-differential.pdf · Code letters GJJ GJK 2006 Volkswagen Touareg REAR DIFFERENTIAL Rear Final Drive Microsoft