Center Differential Housing and Center Differential With Transmission Installed
Center Differential Housing and Center Differential with Transmission Installed
Special tools, testers and auxiliary items required
• Engine/Transmission Jack (V.A.G 1383 A)
• Transmission Support (T10337)
• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/5)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
Removing
- Remove the rear noise insulation by loosening the fasteners - 2 - and - 3 -
• Do not bend the flex joint in the front exhaust pipe by more than 10° or it will be damaged.
- Disconnect the exhaust system at clamping sleeve(s) - arrows -.
- Place the (V.A.G 1782) under the transmission.
- Remove the plug - arrow - and drain the transmission fluid.
- Install the plug - arrow - and tighten it to 40 Nm.
- Remove the bolts - arrows -, and remove the driveshaft heat shield - A - (if equipped).
Driveshaft Bolted on the Transmission Side:
- Remove the bolts that connect the driveshaft to the transmission by counterholding them with the (T10172) and (T10172/5).
- Press the driveshaft together with rear final drive; the universal joint is able to slide axially.
- Secure the driveshaft to the side.
Driveshaft Mounted on the Transmission Side:
- Remove the driveshaft.
All Vehicles:
- Support the transmission using the (V.A.G 1383 A) with the (T10337) attached.
There is the risk of an accident.
• The (V.A.G 1383 A) may only be used during assembly and must not sit unsupervised under the vehicle.
- Remove the bolts from the tunnel cross member - arrows -.
- Lower the transmission to dimension - a - using the (V.A.G 1383 A).
• Dimension - a - = maximum 70 mm.
- Remove the nuts - arrow - and the tunnel cross member.
- Place the (V.A.G 1782) under the transmission.
Danger of damaging the center differential.
• Carefully and slowly pull center differential housing off of transmission toward rear. Otherwise the center differential can fall out of the transmission.
• A center differential that has fallen onto the floor must not be installed again. Any center differential that has fallen out must be replaced.
- Remove the bolts - A - and - arrows - for the center differential housing - B - to the transmission.
- Carefully remove the center differential housing - 6 -, the pressure spring - 3 -, the adjusting shim - 4 - and the plate spring - 5 -.
- Remove the center differential - 2 - and the gear carrier - 1 -.
If the gear carrier - 1 - remains in the center differential housing, proceed as follows:
- Hold the gear carrier - 1 - by one of the side ribs with pliers and remove it in direction of - arrow A -.
- At the same time, carefully hit housing - arrow B - alternating from one side to the other using a rubber hammer.
Danger of damaging the sealing surface on the center differential housing.
• Use a hammer to hit the housing on several places.
• Do not damage sealing surfaces when doing this.
- Remove the center differential.
Installing the Center Differential and Housing
Tightening specifications, refer to => [ Center Differential and Center Differential Housing Overview ] Center Differential and Center Differential Housing Overview
- Thoroughly clean both housing joint surfaces.
Install the gear carrier on the transmission as follows:
• Installed position: The tab on the gear carrier - arrow A - must be inserted into the opening - arrow B - in the transmission housing.
- Slide the center differential - 2 - all the way in direction of the gear carrier - 1 -.
- Install the plate spring - 5 -, the adjusting shim(s) - 4 - and the pressure spring - 3 - in the center differential housing - 6 -.
• Plate spring installation location - 5 -: The camber on the inner diameter - arrow - faces toward the center differential housing - 6 -.
- Apply sealing paste (AMV 188 001 02) evenly and not too thick.
- Then position the center differential housing - 6 - on the transmission.
- Press the center differential housing - B - on until it makes contact with the transmission housing and hold it securely.
- Install and tighten the new bolts - arrows -. Tightening specification => [ (Item 3) Bolt ] Center Differential and Center Differential Housing Overview.
- Tighten the bolts - A -. Tightening specification => [ (Item 1) Bolt ] Center Differential and Center Differential Housing Overview.
- Tighten the tunnel cross member on the transmission mount - arrows -. Tightening specification => [ (Item 1) Nut ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.
- Hoist the transmission and tighten the tunnel cross member bolts - arrows -. Tightening specification => [ (Item 2) Bolt ] Tunnel Crossmember, Transmission Mount and Transmission Support Overview.
- Mount or install the driveshaft on the transmission.
- Install the driveshaft heat shield - A - and tighten the bolts - arrows - to tightening specification.
- Fill transmission oil and check oil level. Refer to => [ Manual Transmission, Checking Transmission Fluid Level ] Service and Repair.
- Install the exhaust system and align it without tension.
- Install the rear noise insulation.
Tightening Specifications
