Transfer Case Cover: Service and Repair

Self-Locking Center Differential Cover

Special tools, testers and auxiliary items required

• Oil collecting and extracting device (VAG 1782)

• Protective glasses

Removing

• Transmission installed.

CAUTION!
Do not let engine run or tow vehicle without gear oil.

• General repair information. Refer to => [ General Repair Information ] General Repair Information.

• Rules of cleanliness for working on transmissions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- Remove the rear noise insulation by loosening the fasteners - 1 and 2 - and, if equipped the - arrow -.





- Remove the tunnel crossmember with the center bracket from the front exhaust pipe.





- Remove the tunnel crossmember - 1 -. Refer to => [ Tunnel Crossmember ] Tunnel Crossmember.





- Remove the heat shield bolts - arrows - and heat shield - a - for the driveshaft.

- Remove the bolts at the transmission/driveshaft flange.

- Push the driveshaft toward the rear final drive. The Constant Velocity (CV) joints can be moved axially.

- Tie the driveshaft up to the side.

- Place the used oil collection and extraction device (VAG 1782) under the transmission.





CAUTION!
Wear protective glasses.

- Loosen and remove the self locking center differential cover bolts - 6 to 1 - in sequence and drain the gear oil.

• The cover has no drain plug, so the gear oil can only be drained by removing the cover.

CAUTION!
Carefully pull the self locking center differential cover off the transmission toward the rear. Otherwise, the self locking center differential can fall out of the transmission.

- Secure the self locking center differential - B - and baffle - A - against falling out or remove from the output shaft toward the rear.





Installing





Install in the reverse sequence; note the following points:

• Replace the transfer case cover O-ring.

If the self locking center differential - B - and baffle - A - were removed:

- Clean the baffle, lubricate with gear oil and insert into the transmission.

• Installation position: The plate - A - on the baffle must be secured with the side tabs via the opening - B - on the transmission.

- Place the self locking center differential - B - on the output shaft splines while rotating slightly.





• Check the installation location of the baffle with plate again - arrow -.

- Check whether the installed self locking center differential can be turned by hand.

- Check whether the baffle plate - arrow - is still secured correctly.

- Place the cover with shaft installed on the self locking center differential, rotating slightly if necessary.

- Tighten the self locking center differential cover bolts as follows:









- Install the driveshaft;

- Install the exhaust system.

- Fill the gear oil in the transfer case. Refer to => [ Transfer Case Gear Oil Filling after Repair ] Transfer Case Gear Oil Filling after Repair.

Tightening Specifications