Transfer box and final drive

Chapter overview

• Technical data
  1
• 1 Overview - drive train
  1
• 2 Transfer box identification
  2
• 2.1 Location on transfer box
  2
• 2.2 Identification code, assembly allocation, capacities
  2
• 3 Identifying front final drive
  8
• 3.1 Location on front final drive
  8
• 3.2 Code letters, allocation, ratios, capacities
  8
• 4 Identifying rear final drive
  15
• 4.1 Location on final drive
  15
• 4.2 Code letters, allocation, ratios, capacities
  15
• 5 General repair notes
  24
• 5.1 Components
  24
• Controls, housing
  26
• 1 Electrical and electronic components and their locations for transfer box
  26
• 1.1 Removing and installing transfer box control unit J646
  28
• 2 Removing and installing transfer box
  30
• 2.1 Removing transfer box
  31
• 2.2 Transporting transfer box
  34
• 2.3 Installing transfer box
  34
• 2.4 Specified torques
  35
• 2.5 Routing breather line on transfer box
  36
• 3 Removing and installing gearbox carrier and bracket
  37
• 3.1 Removing gearbox carrier and bracket
  37
• 3.2 Installing gearbox carrier and bracket
  38
• 4 Renewing bonded rubber bushes in gearbox carrier
  41
• 5 Checking oil in transfer box
  44
• 6.1 Renewing input shaft seal
  54
• 6.2 Renewing output flange oil seal for front propshaft (transfer box installed)
  55
• 6.3 Renewing output flange oil seal for rear propshaft (transfer box installed)
  58
• 7 Removing and installing transfer box motor V253
  62
• 7.1 Removing transfer box motor V253
  62
• 7.2 Installing transfer box motor V253
  63
• Final drive - rear differential
  67
• 1.1 Removing and installing differential lock control unit J647
  69
• 2 Checking gear oil in rear final drive
  71
• 3 Removing and installing rear final drive (Touareg 2003)
  72
• 3.1 Removing rear final drive
  72
• 3.2 Installing rear final drive
  73
• 3.3 Routing breather line for rear final drive
  74
• 4 Removing and installing axle differential lock motor V304
  77
• 4.1 Removing axle differential lock motor V304
  77
• 4.2 Installing axle differential lock motor V304
  77
• 5 Renewing oil seals on rear final drive
  79
• 5.1 Renewing left flange shaft seal, vehicles without differential lock
  79
• 5.2 Renewing left flange shaft seal, vehicles with differential lock
  82
• 5.3 Renewing right flange shaft seal, vehicles without differential lock
  85
• 5.4 Renewing right flange shaft seal, vehicles with differential lock
  87
• 5.5 Renewing propshaft flange oil seal on rear final drive (final drive removed)
  89
• 6 Renewing bonded rubber bush on rear final drive
  95
• 6.1 Installation position of bonded rubber bush
  96
• 6.2 Pulling out and pulling in bonded rubber bush on propshaft flange
  96
• 6.3 Pulling rear bonded rubber bush out and in
  97
• Final drive - front differential
  98
• 1 Checking front final drive oil
  98
• 2 Removing and installing front final drive
  99
• 2.1 Removing front final drive
  99
• 2.2 Installing front final drive
  105
• 2.3 Routing breather line for front final drive
  109
• 3 Renewing oil seals on front final drive
  110
• 3.1 Renewing oil seal for left flange shaft
  110
• 3.2 Renewing seal for right flange shaft
  113
• 3.3 Renewing seal for propshaft flange on front final drive (final drive removed)
  115
• 4 Renewing needle bearing for left flange shaft
  121
• 4.1 Removing needle bearing
  121
• 4.2 Installing needle bearing
  122
• 5 Renewing bonded rubber bush on front final drive
  123
• 5.1 Installation position of bonded rubber bush
  124
• 5.2 Pulling out and pulling in bonded rubber bush on propshaft flange
  125
• 5.3 Pulling out and pulling in bonded rubber bush on front housing
  126
• 5.4 Pulling out and pulling in bonded rubber bush on left flange shaft extension tube
  126
• Final drive - differential
  128
• 1 Removing and installing propshafts
  128
• 1.1 Assembly overview
  128
• 1.2 Removing and installing front propshaft
  130
• 1.3 Removing and installing rear propshaft
  134
• 1.4 Installing centre bearing for rear propshaft free of stress
  139
• 1.5 Removing and installing flexible coupling
  140