Transfer Gear, Removing and Installing

Transfer gear, removing and installing
Tightening torques
Special tools, testers and auxiliary items
VAG1383A engine/transmission jack

Removing
- Disconnect left and right three way catalytic converters from rear exhaust system and press both three way catalytic converters apart.





- Remove heat shield -A- above driveshaft.
- Remove heat shield -B- for driveshaft from cover for Torsion differential (arrows).
- Remove driveshaft from drive flange on transmission.
- Take up weight of transmission from below with VAG1383A and 1359/2 attachment plate.





- Detach heat shield for right transmission mount -1- from transmission support.
- Remove right transmission mount -2-.
- Remove left transmission mount.
Transmission supports (right, -3- and left) remain attached to transmission.
- Place oil drain pan under transmission.
- Drain oil from transfer gear.





- Loosen mounting bolts (arrows) for transfer housing in diagonal sequence and remove.

CAUTION: Remove the transfer gear housing from the back of the transmission slowly and carefully. Otherwise, the Torsion differential could fall out of the transmission.





- Press Torsion differential (complete) to rear, off output pinion (to right, in line with straight arrow).

Installing
The transfer gear is installed in reverse order of removal. In addition, the following work steps have to be carried out:





- Check for presence of dowel sleeves (arrows -A- and -B-).
- Install gasket.
- Slide cleaned magnets into cast holding pocket -1- in intermediate flange.





- Slide Torsion differential onto splines of output shaft and bottom front gear (turn differential slightly when installing).
- Check that Torsion differential can be turned by hand when it is in position.





- Install fully assembled transfer housing (together with front gears and rear drive flange) onto transmission flange.
- Install mounting bolts for transfer housing and tighten to final torque in diagonal sequence in several stages.
- Fill transfer housing with fluid and check oil level.
Tightening torques





Tightening torques