Assembling bevel gear transfer case

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Note list of adjustments → Adjustment overview (bevel gear transfer case) .

Pressing in sleeves for oil supply

Fig 1: Pressing In Sleeves For Oil Supply Using VW 409

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Carefully press in up to stop.

NOTE:

Installation position: Inscribed side to punch
Sleeves can also be driven in using punch VW 409 when bevel gear transfer case is not disassembled.

Pressing roller sleeve into final drive housing

Fig 2: Pressing Roller Sleeve Into Final Drive Housing Using Special Tools T10108 & 30-21

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Carefully press roller sleeve into final drive housing up to stop using sleeve V.A.G 30-21

NOTE:

Writing points toward press tool.

Press large tapered roller bearing inner race onto head bevel gear.

Fig 3: Pressing Large Tapered Roller Bearing Inner Race Onto Head Bevel Gear Using Special Tools VW412, VW402 & 3259

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Place oil deflector ring with cut-out - arrow A - over tab - arrow B - in large cover.

Fig 4: Placing Oil Deflector Ring With Cut-Out Over Tab In Large Cover

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NOTE:

For some transmissions, adjustment shim S ₁ is located between oil deflector ring and large cover. Always re-install the adjustment shim in the same place from which it was removed.

Fig 5: Inserting Adjustment Shim In Large Cover And Pressing In Outer Race For Large Tapered Roller Bearing Using Special Tools VW 407, VW 470/1 & 2007

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Insert adjustment shim S ₁ in large cover and press in outer race for large tapered roller bearing.

Fig 6: Identifying Head Bevel Gear/Input Shaft, Large Cover & Bolts

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Insert head bevel gear/input shaft - 1 - in final drive housing.
Coat new O-ring with oil and install on large cover - 2 -.

NOTE:

Some transmissions have no O-ring. For such transmissions, sealant AMV 188 200 must be applied to sealing surfaces.

Tighten cover with bolts - 3 - , - 4 - and - 5 - uniformly and in diagonal sequence to specified torque.

Fig 7: Identifying Inner Race/Tapered Roller Bearing, Outer Race/Tapered Roller Bearing, Adjustment Shim, O-Ring, Small Cover & Bolts

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Rotate bevel gear transfer case 180 ° in assembly stand.
Install inner race/tapered roller bearing - A - to stop on head bevel gear/input shaft.
Then place outer race/tapered roller bearing - B - and adjustment shim S ₂ - C - on top.
Place a new O-ring - arrow - on sealing surface of small cover - D -.

Insert small cover and tighten bolts - E - to tightening torque.

Fig 8: Pressing Outer Race For Small Tapered Roller Bearing Into Drive Pinion Housing Using Special Tools VW 408A, VW 472/1 & VW 402

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Press outer race for small tapered roller bearing into drive pinion housing.

During the pressing in procedure, the tab - arrow - must be located in front of pressure plate VW 402.

Fig 9: Pressing Outer Race For Large Tapered Roller Bearing Into Drive Pinion Housing Using Special Tools VW 408A, VW 402 & 3253/7

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Press outer race for large tapered roller bearing into drive pinion housing.
Insert shaft bevel gear with adjustment shim S ₄ and inner race for large tapered roller bearing into final drive housing.
Coat adjustment shim S ₃ with sealant on both sides and attach to final drive housing.

Fig 10: Identifying Drive Pinion Housing, T10049 & T10108

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Install drive pinion housing - 1 - , insert bolts with sealant while doing so.
Insert small inner race/tapered roller bearing for shaft bevel gear.
Drive in new sealing ring for output flange to stop using thrust piece T10049.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

Grease splines of output flange and on shaft bevel gear evenly with multi-purpose grease.

Fig 11: Identifying Two Arm Puller, T10108, 40-105 & VW 516

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Pulling in output flange

A - Two arm puller , e.g. Kukko 20/10

Attach pulling hook on underside of drive pinion housing.
Coat threads of new hex nut and of shaft bevel gear with locking fluid D 000 600.
Tighten new hex nut for output flange to specified torque.

Fig 12: Identifying Socket Wrench Insert, VW 313, T10108, T10108/1 & V.A.G 1601

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Socket wrench insert - A - for drive 3/4 inch

Fig 13: Driving In New Seal For Right Flanged Shaft Using Special Tools VW 313, T10049 & T10108

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Drive in new seal for right flanged shaft to stop
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

Fig 14: Pressing In Right Flanged Shaft Using Special Tools VW 407, VW 402, VW 401, VW 470 & 3253/5

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Carefully press in right flanged shaft, turning shaft while doing so.
After pressing in, check whether flanged shaft can still be turned.
If necessary, use a plastic mallet to knock opposite side of flanged shaft.