Transfer Case, Removing And Installing: Removing

Fig 1: Identifying Front/Rear Noise Insulation

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-- Activate the vehicle lift mode if the vehicle has air suspension. Refer to Self-Leveling Suspension .

-- Remove the rear Drive Axle. Refer to REAR DRIVE SHAFT, REMOVING AND INSTALLING .

-- Remove the bolts and the rear noise insulation -2-.

-- Disconnect electrical connectors -1, 2, 3- from the transmission.

Fig 2: Connect Connectors -1 Through 3-

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Vehicles with a 3.0L TFSI Engine:

Fig 3: Identifying Bolts -1, 2, 3- And Bracket -4-

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-- Remove the bolts -1, 2 and 3-.

-- Remove the bracket -4-.

Vehicles with a 3.0L TDI Engine:

Fig 4: Identifying Bolts

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-- Remove bolts -arrows- on the particulate filter mount.

Vehicles with a 4.2L TDI Engine:

-- Remove left and right bolts -arrows- on the particulate filter mount.

All Vehicles:

Fig 5: Identifying Driveshaft Bolts -Arrows-

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-- Remove the bolts -arrows- that connect the front Driveshaft to the transfer case.

-- Use the Counterhold - Kit - Multiple UseT10172 and adapters T10172/6.

-- Tie the front Driveshaft to the body.

-- Slide the T40093/6 onto the T40091/1.

Fig 6: Identifying Crossmember T40091/1 And Adapters

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-- Slide the T40091/1 into the T40091/4 and T40091/5 tighten it with the bolts -arrows-.

-- Tighten the adapter to the body using the bolts -A-.

• Tighten the left adapter T40091/5 to 30 Nm with an M10 x 30 bolt.
• Tighten the right adapter T40091/4 to 23 Nm with an M8 x 30 bolt and washer.

-- Attach the Engine/Gearbox Jack - Gearbox Support3282 to the transfer case with an M8 x 20 bolt -arrow A- and an M10 x 20 bolt -arrow B-.

Fig 7: Identifying Engine/Transmission Jack V.A.G 1383A And Transmission Support 3282

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-- Attach the 3282/45 to the right Engine/Gearbox Jack - Gearbox Support with an M8 nut.

-- Fit the 3282/45 onto the left Engine/Gearbox Jack - Gearbox Support with a washer -1-.

-- Remove the bolts -1 and 2- from the Engine/Gearbox Jack - Gearbox Support.

Fig 8: Identifying Transfer Case Support Bolts -1 And 2-

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-- Lower the transfer case using the Engine/Gearbox JackVAG 1383A to dimension -a-, between the body and the Engine/Gearbox Jack - Gearbox Support -1-.

Fig 9: Identifying Dimension -A- Between Body And Transmission Support -1-

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• -a- = approximately 50 mm

-- Install the T40091/6 with the T40091/7 in the T40093/6.

Fig 10: Identifying Engine Support Basic Set T40091, Spindle T40091/6, Square Nut T40091/7 And Adapter T40093/6

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-- Attach the T40091/6 with the T40091/8 to the automatic transmission housing.

-- Tighten the nut -A- to prevent the T40091/6 from turning.

-- Remove the bolts connecting the transmission to the transfer case -arrows 1- and -arrows 2-.

Fig 11: Identifying Transfer Case Bolts -Arrows 1 And 2-

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-- Remove the transfer case from the transmission.

-- If replacing the transfer case, remove the Engine/Gearbox Jack - Gearbox Support -arrows- and bracket -bolts 1 and 2-. Refer to TRANSMISSION CARRIER AND CONSOLE OVERVIEW .

Fig 12: Identifying Bolts -Arrows- And Transfer Case Bracket

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