Gear oil in transmission, transmissions with combined oil systems, filling after repair

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

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

Fig 2: Identifying Engine/Transmission Jack V.A.G. 1383 A

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Engine/Transmission Jack V.A.G 1383 A
Safety glasses

Conditions

→ Differentiation of separate or combined oil systems

Axle oil temperature approx. 20°C (room temperature) to max. 50°C.
Vehicle level.
The vehicle must not be started or towed without gear oil.

The transmission must be filled after the following work or repairs:

Fig 3: Transmission Oil Cooling, Return Line, Supply Line, Transfer Case, Protective Pipe & Front Final Drive

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The transfer case cover - 3 - was removed and gear oil was completely drained.
The front final drive cover - 6 - was removed and gear oil was completely drained.
The axle oil cooler - 1 - was removed.

NOTE:

The oil spaces in the front final drive and transfer case are consolidated. Therefore, they must always be checked and filled together.
Both insufficient filling and overfilling affect the transmission function.
Observe disposal regulations.

Work procedure

The transfer case and front final drive have a combined oil system, but must be filled and checked separately in succession due to the different oil levels.

Fig 4: Noise Insulation Panel Quick Release Fasteners

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Remove both 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 5: Bolt M12X100 With Attached Nut Inserted In Mount Behind Transmission Oil Pan

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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 6: Oxygen Sensor Electrical Connectors & Tunnel Cross Member Bolts

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If present, remove oxygen sensor electrical connectors - 1 - and - 2 - from tunnel cross member - arrows -.
Mark installed position of transmission tunnel cross member on body.

Fig 7: Transmission Bolts On Tunnel Cross Member

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Remove left - 1 - and right - 2 - transmission bolts on tunnel cross member.

Fig 8: Removing/Installing Bolts At Tunnel Cross Member

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Remove transmission tunnel cross member - arrows - from body.
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 9: Transfer Case Oil Inspection And Filler Plug

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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 10: Transfer Case Oil Inspection And Filler Plug

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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.

Fig 11: Oil Inspection And Filler Plug

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Remove front final drive oil inspection and filler plug - arrow -.

Axle oil specification , capacities → Capacities

Slowly and evenly fill front final drive with axle oil over a duration of at least 5 minutes until oil escapes at lower edge of the oil filler hole.

NOTE:

The filling time of at least 5 minutes is necessary for the internal oil level to even out.

Fig 12: Transfer Case Oil Inspection And Filler Plug

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Fill transfer case housing with axle oil using a hose and sprayer or pump in oil filler hole - arrow - over a duration of at least 5 minutes.

Axle oil specification , capacities → Capacities

NOTE:

The filling time of at least 5 minutes is necessary for the internal oil level to even out.

After removing the hose, a small amount of axle oil always escapes and stands in oil channel above bolt.

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

If no axle oil comes out:

Add axle oil again until oil level is correct.
Allow extra axle oil to drain from oil filler hole.
Install old oil inspection and filler plug.
Install tunnel cross member → Tunnel cross member, removing and installing .

Performing road test

CAUTION: Overfilling or under filling the axle oil leads to transmission damage.

Follow all instructions precisely.

Before checking the oil level, a short road test must be done to bleed the oil system.

Drive vehicle for 5 minutes at approx. 40 km/h, at least 4 km.

NOTE:

Ensure the axle oil cooler is filled with transmission oil. Because the transfer case oil pump is only operated when driving, a short drive is necessary.

After the road test:

Axle oil level, checking and adjusting → Gear oil level in transmission, transmissions with combined oil systems, checking

Torque specification

Component	Nm
Transfer case oil inspection and filler plug	20
Front final drive oil inspection and filler plug	35