Volkswagen Touareg 2004-06

Transfer Case Removal & Installation

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The transfer case is removed together with the engine, front final drive and transmission. The procedure for this is described in this section under Engine Assembly removal and installation.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine.
  4.  
  5. Remove the driveshaft between the transfer case and the front final drive. Counterhold the driveshaft using tool T10172 or equivalent to ease removal of the bolts.
  6.  
  7. Support the transfer case with a hoist.
  8.  
  9. Remove the bolts, then separate the transfer case and set it aside.
  10.  

To install:

  1. Check if the alignment sleeves for centering the transmission/transfer case are installed in the transmission; install if necessary.
  2.  
  3. Always replace the O-ring seal between the transfer case and transmission; lubricate it lightly.
  4.  
  5. Lubricate the transfer case input shaft and transmission output shaft with grease G 000 100 or equivalent.
  6.  
  7. Push the transfer case completely onto the transmission, ensuring that transfer case input shaft splines are centered as they are guided onto the transmission output shaft.
    NOTE
    If the splines are correctly positioned, the transfer case will slide to a stop against the transmission. Do not use the bolts to pull the transfer case onto the transmission!

  8.  
  9. The remaining installation is the reverse of removal. Observe the following torque specifications:

    Transfer case mounting bolts (use new): 33 ft. lbs. (45 Nm)
     
    Transfer case damper: 24 ft. lbs. (32 Nm)
     

  10.  

 
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