Self-locking center differential, removing and installing

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

Special tools, testers and auxiliary items required

Fig 1: Alignment Fixture 3350

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Alignment fixture 3350

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/Transmission Jack V.A.G 1383 A
Bolt M12x100 with nut

Removing

NOTE:

The removal and installation is described on a vehicle with 10-cyl. FSI engine.

Fig 3: Identifying Exhaust Pipe Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

On vehicles equipped with auxiliary heater, remove bolts - arrows - for exhaust pipe of auxiliary/additional heater to noise insulation.

Fig 4: Noise Insulation Quick-Release Fasteners

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Loosen quick-release connectors - 1 - and - 2 - and remove noise insulation.
Remove left Y-pipe →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
.

Fig 5: Removing/Installing Heat Shield For Driveshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove heat shield - A - for drive shaft - arrows -.
Remove bolts on transmission/drive shaft connection.
Slide drive shaft back to rear final drive and together; the constant velocity joints can slide axially.

Fig 6: Removing Bolt At Right Exhaust Tract Strap

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Remove bolt - arrow - at right exhaust tract strap.

Fig 7: Tunnel Cross Member Bracket Bolts

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Remove bracket - arrow - from tunnel cross member.

Fig 8: Oxygen Sensor Electrical Connectors & Tunnel Cross Member Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bracket for oxygen sensor electrical connectors - 1 - and - 2 - from tunnel cross member - arrows -.

NOTE:

The electrical connectors remain connected.

Fig 9: Tunnel Cross Member Bolts

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Remove tunnel cross member bolts - arrows -.
Remove bolts - 1 - and - 2 - and remove tunnel cross member.

Fig 10: Supporting Engine Carrier And Subframe With Engine/Transmission Jack V.A.G 1383 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Support engine carrier and subframe using Engine/Transmission Jack V.A.G 1383 A as shown in illustration.

Fig 11: Transmission Mount & Lower Subframe Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove transmission mount bolts - 3 -.
Remove bolts - 1 - and - 2 - and carefully lower subframe using Engine/Transmission Jack V.A.G 1383 A.

Fig 12: Right Transmission Support Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - arrow - at rear of right transmission support.
Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

CAUTION: The self-locking center differential can fall out of the transmission when its cover is removed.

Fig 13: Self-Locking Center Differential Cover And Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - on self-locking center differential cover in a diagonal sequence.
Allow escaping oil to drain into Used Oil Collecting and Extracting Device V.A.G 1782.
Slowly and carefully remove cover together with self-locking center differential from transmission.

Installing

NOTE:

If the self-locking center differential is replaced, a new ball bearing must be pressed on.

Fig 14: Pressing Ball Bearing Onto Self-Locking Center Differential Using Shop Press With Assembly Fixture 3350

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press ball bearing - 2 - as far as stop onto self-locking center differential - 1 - under shop press with Carrier Bearing Inst. Tool 3350.

Fig 15: Checking Installation Depth Of Bearing Race With A Depth Gauge

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press bearing race - 1 - as far as stop into front final drive intermediate flange.
Check installation depth of bearing race with a depth gauge.

Dimension - a - = approx. 9 mm

If dimension - a - is noticeably smaller, the bearing race has slipped.

Remove bearing race and check it for correct installation position.

The tabs on rear side of the bearing race must engage in corresponding cut-outs on front final drive intermediate flange.

Fig 16: Identifying Whether Shim

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Check whether shim - 1 - is still inserted.
Replace rear flange shaft seal, replace if damaged → Rear flange shaft seal, replacing .

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

Fig 17: Self-Locking Center Differential Tightening Sequence

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Tighten self-locking center differential cover bolts in 2 stages as follows:

Stage	Tightening
I	Pre-tighten bolts - 1 - and - 2 - to 3 Nm.
II	Tighten bolts - 1 to 7 - to 16 Nm in sequence.

Further installation is in reverse order of removal, note the following:

Fill gear oil in transfer case → Gear oil in automatic transmission .

NOTE:

Bring transmission into installation position using Engine/Transmission Jack V.A.G 1383 A

Install transmission support and transmission mount → Rear transmission supports and transmission mounts, removing and installing ,
Install subframe → 40 - FRONT SUSPENSION .
Install drive shaft, observe allocation: → 39 FINAL DRIVE, DIFFERENTIAL .
Install exhaust system and align it free of tension →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
.

Torque specification

Component	Nm
Tunnel cross member to chassis	40