Self-locking center differential cover, removing and installing

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

NOTE:

Rules of cleanliness for working on automatic transmissions → Rules of cleanliness for working on automatic transmissions .
General repair notes → Repair instructions .

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.

Removing

CAUTION: Do not start or tow vehicle with self-locking center differential removed or when gear oil has been drained.

Fig 2: Self-Locking Center Differential Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

The cover for self-locking center differential is secured to transmission with 7 bolts.
The cover has no oil drain plug, so the gear oil can only be drained by removing cover.
The right transmission support is secured to the self-locking center differential cover with a bolt. This bolt must be removed. The transmission support must not be removed completely, however, all steps for removing the transmission support must be followed in order to remove the cover (e.g. drive shaft must be unbolted and tied up to side, rear of transmission must be lowered (→ Rear transmission supports and transmission mounts, removing and installing ).

Fig 3: Removing Transmission Supports With Transmission Mounts From Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: Wear eye protection.

Fig 4: Self-Locking Center Differential Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: Carefully pull self-locking center differential cover off transmission toward the rear.

Otherwise, the self-locking center differential can fall out of the transmission.

Secure self-locking center differential from falling out or pull it rearward and off from output shaft.

Installing

Installation is in reverse order of removal, note the following:

If shim has fallen out:

NOTE:

The shim must be the correct size and must not be replaced by a shim with a different thickness.

Fig 5: Removing/Installing Torsen Differential Onto/From Splines Of Output Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If self-locking center differential was removed:

Place self-locking center differential on output shaft splines, rotate slightly.
Check whether installed self-locking center differential can be turned by hand.
Place cover with shaft installed on self-locking center differential, rotating slightly if necessary.
Replace O-ring in self-locking center differential cover.

Fig 6: Self-Locking Center Differential Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tightening sequence:

Tighten bolts - 1 - and - 2 - to 3 Nm.
Tighten bolts - 1 through 7 - in sequence shown to specified torque.
Follow all steps as described for installing right transmission support → Rear transmission supports and transmission mounts, removing and installing .
Top off and check gear oil in transfer case after repair → Gear oil in transfer case, transmissions with separate oil systems, filling after repair .

Torque specification

Component	Nm
Self-locking center differential housing to transmission housing	16