Gear oil level in transfer case, transmissions with separate oil system, checking

WARNING: This page is about a different variant/trim than selected.

Special tools, testers and auxiliary items required

Fig 1: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Old oil collecting and extracting device V.A.G 1782
Safety glasses

Test condition

Axle oil temperature approx. 20°C (room temperature) to max. 50°C.
Vehicle level.

→ Differentiation of separate or combined oil systems

Work procedure

Fig 2: Noise Insulation Panel Quick Release Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rear noise insulation by loosening bolts - 2 - , - 3 - and - 4 -.

CAUTION: For the following steps, notice:

Do not support on transmission oil pan - risk of damage.

Fig 3: Bolt M12X100 With Attached Nut Inserted In Mount Behind Transmission Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert a bolt M12x100 - 1 - with attached nut - 2 - in mount behind transmission oil pan.

Dimension - a - = 13 mm.

Position Engine/Transmission Jack V.A.G 1383 A plunger on bolt head and slightly raise transmission, as shown in illustration.
Remove bracket for noise insulation below ATF cooler.

Fig 4: Oxygen Sensor Electrical Connectors & Tunnel Cross Member Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If present, remove oxygen sensor electrical connectors - 1 - and - 2 - from tunnel cross member - arrows -.

Fig 5: Transmission Bolts On Tunnel Cross Member

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark installed position of transmission tunnel cross member on body.
Remove left - 1 - and right - 2 - transmission bolts on tunnel cross member.

Fig 6: Removing/Installing Bolts At Tunnel Cross Member

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove transmission tunnel cross member from body - arrows -.
Lower or raise transmission accordingly using Engine/Transmission Jack V.A.G 1383 A until transmission is horizontal in installation position again.

NOTE:

The transmission must be level to check the axle oil.
It must be raised or lowered accordingly using Engine/Transmission Jack V.A.G 1383 A after removing the tunnel cross member.

Fig 7: Transfer Case Oil Inspection And Filler Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide tunnel cross member as far back as possible so that transfer case oil inspection and filler plug - arrow - is accessible.
Place used oil collection and extraction device V.A.G 1782 under transmission.

NOTE:

Observe disposal regulations.

CAUTION: Wear eye protection.

Remove transfer case oil inspection and filler plug - arrow -.

Fig 8: Transfer Case Oil Inspection And Filler Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

The transfer case oil inspection and filler plug is located at the side of the transfer case housing and is installed from below - arrow -.
In the illustration, the transfer case is partially shown from behind so that the axle oil level with filler opening is visible.

A small amount that is in the oil channel above the bolt always escapes first.

If axle oil drains lightly from the opening, the oil level in the transfer case is correct.

If no axle oil comes out:

Add gear oil using a hose and a sprayer or pump in the oil inspection hole in the transfer case housing until oil level is correct, specification .
Allow extra axle oil to drain from oil filler hole.

NOTE:

It is not necessary to check the oil level again at this stage.

Always replace oil inspection and filler plug.
Install new oil inspection and filler plug.
Install tunnel cross member → Tunnel cross member, removing and installing .

Rest of installation is in reverse order of removal.

Torque specification

Component	Nm
Oil inspection and filler plug	20