Transfer Case, Disassembling And Assembling

WARNING: This page is about a different car, the 2024 Audi SQ7, 2024 Audi Q7, 2023 Audi SQ7, and 2023 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Assembly Device:T40381
Assembly Device - Assembly Aid:T40381/2
Puller - Grease Cap:VW637/2
Press Piece - Bushing:3118
Press Piece - 37mm:VW416B
Press Piece - Multiple Use:VW447H
Press Piece - Multiple Use:VW447I
Bearing Installer - Differential Bearing:VW511
Splitter:VAS251411
Used Oil Collection And Extraction Unit:SMN372500
Pneumatic Hydraulic Press:VAS6654

Double Shaft Seal Leak:

Fig 1: Double Shaft Seal Leak:

Courtesy of AUDI

If oil leaks out of the oil overflow hole -arrow-, the double shaft seal between the ATF and the transmission fluid is damaged.
For this repair the transfer case must be disassembled and assembled.

Removing

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Remove the self-locking center differential. Refer to CENTER DIFFERENTIAL, REMOVING AND INSTALLING .

Fig 2: Transfer Case End Cover Tightening Sequence (0BL/0D6/0D7)

Courtesy of AUDI

CAUTION:

Damage to the Transmission Support Due to Parts Falling Out.

- When removing the intermediate housing transmission parts can fall out.

- Damaged or fallen bearings and shafts cannot be replaced, because complex measuring methods are required for this which cannot be performed using the customer service tools.

- Perform the following steps with the greatest possible care.

-- Position the :SMN372500 under the transfer case, to catch any transmission parts which may fall out.

-- Remove all bolts and carefully remove the intermediate housing.

-- Remove the shaft -1-.

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-- Remove the shaft -2- with the bearing -1-.

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-- Remove the bolt -1- and the sealing washer -2-.

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-- Position the old seal -1- to protect the housing sealing surface and pry out of the pinion shaft -2- using the :VW637/2 .

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-- Pay attention, that the shim -1- does not get lost.

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Seal - Replacing:

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-- Position the :VAS251411 , :VW416B and :VW447H as shown and pry out the tapered roller bearing using the :VAS6654 .

-- Push on the new seal using the :T40381/1 the open side is downward.

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-- Support the drive pinion gear on the :VW511 and carefully push on the tapered roller bearing -arrow- with the :3118 and :VW447I .

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-- Check if the spacer -1- is installed.

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-- Push in the drive pinion gear all the way using the :T40381/2 in the transmission housing in direction of -arrow-.

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Install in Reverse Order of Removal, While Noting the Following:

-- Install new bolt -1- with a new sealing washer -2- and tighten. Refer to OVERVIEW - TRANSFER CASE .

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Transmission with Oil Pump:

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Depending on the version in the transfer case an additional oil pump is installed.

-- When installing the transfer case pay attention that the oil pump drive matches the transmission input shaft.

-- For this the transmission input shaft must be turned by turning on the front wheels.

-- Release the parking lock to do so and secure the parking lock gear with a cable tie -arrow-.

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Continuation for All Transmissions:

-- Install the transfer case housing and tighten to the tightening specification. Refer to Figure.

-- Install the self-locking center differential. Refer to CENTER DIFFERENTIAL, REMOVING AND INSTALLING .

-- Install the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .