Torsen differential cover, removing and installing

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

NOTE:

General repair instructions → Repair instructions .
Observe rules for cleanliness when working on automatic transmission → Rules for cleanliness when working on automatic transmission .

Special tools, testers and auxiliary items required

Fig 1: Drip Tray V.A.G 1306

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray V.A.G 1306
Safety glasses

Removing

CAUTION: Do not start or tow vehicle with Torsen differential removed or when gear oil has been drained.

Fig 2: Self-Locking Center Differential Tighten Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

The cover for Torsen 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.

Fig 3: Removing Transmission Supports With Transmission Mounts From Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Follow all steps as required for removing right transmission support → Rear transmission supports and transmission mounts, removing and installing .
Remove right transmission support from Torsen differential cover.

NOTE:

The right transmission support is secured to cover for Torsen differential with a bolt. This bolt must be removed.
The transmission support must therefore not be removed completely, however, all steps for removing the transmission support must be followed in order to remove the cover (e.g. driveshaft must be unbolted and tied up to side, rear of transmission must be lowered (→ Rear transmission supports and transmission mounts, removing and installing ).

Fig 4: Self-Locking Center Differential Tighten Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place drip tray V.A.G 1306 under transmission.

CAUTION: Wear eye protection.

Remove bolts from Torsen differential cover for in reverse order of tightening sequence shown in illustration.
Drain gear oil.

CAUTION: Carefully pull Torsen differential cover off transmission toward the rear. Otherwise, the Torsen differential could fall out of the transmission.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure Torsen differential to prevent it falling or pull it from output shaft toward rear.

Installing

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

If the shim has fallen out:

Clean shim, lubricate with gear oil and insert into transmission.

NOTE:

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

Replace O-ring on transfer case cover.

If the Torsen differential was removed:

Fig 6: Removing/Installing Torsen Differential Onto/From Splines Of Output Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide Torsen differential onto splines of output shaft while turning slightly.
Check that Torsen differential can be turned by hand when it is in position.
Place Torsen differential cover with shaft installed onto Torsen differential, turning slightly if necessary.

Fig 7: Self-Locking Center Differential Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install cover for Torsen differential.

Tightening sequence:

Tighten bolts - 1 - and - 2 - to 3 Nm.
Tighten bolts - 1 to 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 → Transfer case gear oil, topping off after repairs .

Tightening torque

Component	Nm
Torsen differential housing to transmission housing	16