Service Notes
TRANSFER GEAR, SERVICING
Special Tools, Testers And Auxiliary Items
^ VW401 thrust plate
^ VW402 thrust plate
^ VW407 punch
^ VW412 thrust disc
^ VW454 thrust tube
^ 3118 press support
^ 40-20 sleeve
CAUTION: If the ATF oil pan is removed, or there is no ATF in the transmission, DO NOT start the engine or tow the vehicle.
NOTES:
^ The parts shown in the illustration can be removed while the transmission is installed.
^ Rules of cleanliness for working on the automatic transmission.
^ Refer to General Repair Instructions.
1. Bolt
^ 25 Nm (18 ft. lbs.)
2. Drive flange, rear
3. Seal
^ For rear drive flange -2-
^ Replacing
4. Bolt
^ 23 Nm (17 ft. lbs.)
^ For housing cover -5-
^ Qty: 4
5. Housing cover
6. O-ring
^ Lubricate with gear oil
7. Circlip For ball bearing -8- on front gear 1 (item -9-)
8. Grooved ball bearing
^ For front gear 1 (item -9-)
^ Pressing off refer to Fig. 1
^ Pressing on refer to Fig. 2
9. Front gear 1
^ For rear axle drive
^ If damaged, only replace together with front gear 2 (item -17-)
^ To remove and install, pull out of transfer housing -13- towards rear, together with items -7- and -8-
10. Circlip
^ For needle bearing -11-
11. Needle bearing
^ For front gear 1 (item -9-)
^ Remove bearing only to replace
^ To replace bearing, heat transfer housing (item -13-) to approx. 100°C (212°F) and drive needle bearing out to back using a drift
^ Drive in to stop using 30-21 sleeve
12. Bolt
^ 23 Nm (17 ft. lbs.)
^ Loosen and tighten in diagonal sequence
13. Transfer housing
14. Tensioning nut
^ For rear drive flange -2-
15. Needle bearing
^ For front gear 2 (item -17-)
^ Only remove bearing in order to replace
^ Replacing
16. Circlip
^ Secures needle bearing -15- in transfer housing -13-
17. Front gear 2
^ For rear axle drive
^ If damaged, always replace together with front gear 1 (item -9-)
^ To remove and install, remove transfer housing -13- and pull out together with items -18-, -19- and -23-
18. Grooved ball bearing
^ For front gear 2 (item -17-)
^ Pressing off refer to Fig. 3
^ Pressing on refer to Fig. 4
19. Circlip
^ Secures grooved ball bearing -18- in transfer housing -13-
20. Plate
^ For grooved ball bearing (item -18-)
^ Before installing, clip on alignment plate -21-
21. Alignment plate
22. Bolt
^ 10 Nm (7 ft. lbs.)
^ For plate -20-
23. Circlip
^ Secures grooved ball bearing (item -18-) on front gear 2 (item -17-)
24. Gasket
^ Replacing
25. Torsion differential
^ Replace complete unit if damaged
^ Removing and installing
26. Double seal
^ Replacing
27. Magnet
^ Removing and installing
28. Dowel sleeve
^ Quantity: 2
29. Breather
^ For transfer gear
^ Cap is installed on breather
^ Installation location: without cover, breather must project 10 - 11 mm (0.39 - 0.43 inch) out of housing
30. Bolt
^ 23 Nm (17 ft. lbs.)
31. Intermediate flange for front final drive
32. Gasket
^ Replacing
33. Dowel sleeve
34. Drive pinion
^ For front final drive
^ Removing and installing
35. Intermediate pinion
^ For front final drive
^ Position: gear identification faces towards transfer gear
36. Output pinion
^ For front final drive
^ Position: gear identification faces towards transfer gear
37. Double seal
^ Replacing
Fig, 1 - Pressing off grooved ball bearing for front gear 1
Fig. 2 - Pressing on grooved ball bearing for front gear 1
Fig. 3 - Pressing off grooved ball bearing for front gear 2
Fig. 4 - Pressing on grooved ball bearing for front gear 2