3.6L FSI
Transfer Case
Special tools, testers and auxiliary items required
• Transmission support (3282)
• Engine/transmission jack (V.A.G 1383 A)
• Counterhold tool (T10172) with adapters (T10172/6)
• Engine Support Basic Set (T40091)
• Adapter (T40093/6) from engine support supplement set (T40093)
Removing
- On vehicles with air suspension, activate vehicle lifting mode.
- Raise vehicle.
- Remove screws and remove rear noise insulation - 2 -.
- Remove noise insulation bracket - arrows -.
- Disconnect exhaust system at double clamps. Remove catalytic converters - 1 - by removing bracket - 2 - and - 3 - from body and bracket - 4 - from transmission carrier.
• The catalytic converters - 1 - must be removed so that the front exhaust pipe decoupling elements are not damaged from the engine/transmission assembly moves.
- Remove rear driveshaft - 5 - from transfer case. Refer to => [ Rear Driveshaft ] Rear Driveshaft.
- Tie up rear driveshaft to body.
- Remove bolts - arrows - at transfer case/front driveshaft connection.
- Use the counterhold tool (T10172) with the adapters (T10172/6) to do this.
- Slide driveshafts forward together. CV joints can be moved axially.
- Tie up front driveshaft to body.
For vehicles with automatic transmission:
- First tighten left adapter (T40091/5) and right adapter (T40091/4) bolts - A - (M10 x 30) by hand to the front M10 threaded hole - B - to the body.
• Do not use the M8 threaded holes - C - for mounting the exhaust system.
- Slide adapter (T40093/6) onto the engine support (T40091/1).
- The push the engine support (T40091/1) into the adapter (T40091/4) and (T40091/5) and secure it with the bolts - arrows -.
- Tighten bolts - A - for adapter to the body to approximately 30 Nm.
All Vehicles
The transmission support (3282) must be used to remove the transfer case as follows:
- Install bolt (3282/45), bolt (3282/54) and Mounting Elements - A - as illustrated.
- Place Engine/Transmission Jack (V.A.G 1383 A) under the vehicle.
The smaller bolt - arrow - from the transmission mount (3282) faces drive direction.
- Secure transmission mount to the transfer case with the M10 x 25 bolt and nut - arrow A - and to the output flange with the M10 x 20 bolt - arrow B -. While doing this, the mounting point for the bolt - arrow B - on the output flange must point upward.
- Attach transmission mount to the transmission mount with the M8 nuts - arrows -.
- Remove transmission carrier bolts - 1 - and - 2 -.
For vehicles with manual transmission:
- Place a suitable piece of wood - A - approximately 50 mm thick between the transmission and the subframe.
- Lower Engine/Transmission Jack (V.A.G 1383 A) until manual transmission rests on block of wood.
- Remove bracket with Back-Up Light Switch (F4) electrical wire to manual transmission from transfer case. Tie electrical wiring up to body.
For vehicles with automatic transmission:
- Lower transfer case using the engine/transmission jack (V.A.G 1383 A) to dimension - a -, between the body and transmission mount - 1 -.
• Dimension - a - = approximately 50 mm
- Install spindle (T40091/6) with the square nut (T40091/7) into the adapter (T40093/6).
- Mount the spindle (T40091/6) and the press sleeve (T40091/8) to the automatic transmission housing.
- Secure nut - A - to prevent the spindle (T40091/6) from turning.
All Vehicles
- Remove transfer case/transmission bolts - arrows 1 - and - arrows 2 -.
- Remove transfer case from transmission.
- Remove transmission carrier - arrows - and bracket bolts - 1 to 2 - from transfer case, for example when replacing transfer case. Refer to => [ Transmission Support and Bracket Assembly Overview ] Description and Operation.
Installing
Install in reverse order, paying attention to the following:
- Ensure alignment sleeves are seated correctly between transfer case and transmission.
- Ensure no lines are kinked when sliding transfer case and transmission together.
- Align transfer case bolting flange so that it is parallel to the flange/transmission. While doing so, adjust the transmission mount (3282) using spindles - A - and - B -.
- Push transfer case completely onto transmission, ensuring that transfer case input shaft splines are centered as they are guided onto the transmission output shaft.
• If necessary turn the rear output flange/driveshaft - C - back and forth.
• If splines are correctly positioned and centrally aligned, the transfer case will slide to stop against transmission.
• Do not use bolts to pull transfer case onto the transmission, otherwise transfer case will distort.
- Tighten bolts - arrows 1 - and - arrows 2 - to tightening specification.
- On vehicles with manual transmission, install Back-Up Light Switch (F4) electrical wire to manual transmission on transfer case.
- Raise transfer case again slightly using Engine/Transmission Jack (V.A.G 1383 A).
- Tighten new transmission carrier bolts - 1 - and - 2 -. Refer to => [ Transmission Support and Bracket Assembly Overview ] Description and Operation.
- Attach rear driveshaft with the new bolts to the transfer case. Refer to => [ Rear Driveshaft ] Rear Driveshaft.
- Attach front driveshaft with new bolts to the transfer case. Refer to => [ Front Driveshaft ] Front Driveshaft.
- Install exhaust system tension-free.
- Install rear noise insulation.
- On vehicles with air suspension, deactivate lift mode.
Tightening Specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.
• Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
• Do not use degreased parts.
• Tolerance for tightening specification ± 15%.
