Disassembling 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.

Drain gear oil.

Fig 1: Identifying Nuts, VW 313 & T10108

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Set bevel gear transfer case on hole - arrow - designated with number - 4 - in transmission holder.
Align bevel gear transfer case to remaining 3 holes and secure.

Nut - A - - M12 x 1.0 (qty. 4)

Fig 2: Identifying Socket Wrench Insert, VW 313, T10108, T10108/1 & V.A.G 1601

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Secure output flange for bevel gear transfer case using stop plate T10108/1.
Remove hex nut for output flange.

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

Fig 3: Identifying Extractor T10037, Knurled Nut T10037/1, Lower Support & T10108

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Screw extractor T10037 onto right flanged shaft.
Align extractor parallel to flange using knurled nut T10037/1 and lower support - A -.
Pull out flanged shaft.
If seal must be replaced, remove it now.

Fig 4: Identifying Three Arm Puller, VW 313 & T10108

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Pull off output flange with seal and bearing inner race.

A - Three arm puller , e.g. Kukko 45-2

Place thrust pad V.A.G 40-105 on output flange.

Fig 5: Pulling Bearing Inner Race Off Output Flange Using Tapered Roller Bearing Puller

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Pull bearing inner race off output flange using tapered roller bearing puller.
Remove seal from output flange.

Fig 6: Identifying Drive Pinion Housing, Two Arm Puller & T10108

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Swing bevel gear transfer case so that drive pinion housing - 1 - points upward.
Unscrew hex bolts for drive pinion housing on final drive housing.
Pull off drive pinion housing.

A - Two arm puller , e.g. Kukko 20/10 with hook Matra V/170

Remove adjustment shim S ₃ .
Remove shaft bevel gear with adjustment shim S ₄ and inner race for large tapered roller bearing out of final drive housing.
Clean locking fluid residue from threads on shaft bevel gear.

NOTE:

Drive pinion housing can also be removed and installed with assembled output flange.
Clean sealant from sealing surfaces of drive pinion housing on final drive housing and adjustment shim S ₃ .
Also clean threaded holes in final drive housing as well as hex bolts for securing drive pinion housing.

Fig 7: Pressing Small Tapered Roller Bearing Outer Race Off Drive Pinion Housing Using VW 402 & 3138

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Press small tapered roller bearing outer race off drive pinion housing

Fig 8: Pressing Large Tapered Roller Bearing Outer Race Off Drive Pinion Housing Using 3138

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Press large tapered roller bearing outer race off drive pinion housing.

Fig 9: Identifying Bolts, Small Cover, Inner Race/Tapered Roller Bearing, Large Cover, Head Bevel Gear/Input Shaft, VW 313 & T10108

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Remove four bolts - 1 - for small cover - 2 -.
Remove small cover with outer race/tapered roller bearing and adjustment shim S ₂ .
Pull off inner race/tapered roller bearing - 3 - from head bevel gear/input shaft - 5 -.

NOTE:

Inner race can be removed by hand. If necessary, lift carefully at head bevel gear/input shaft after removing large cover and then remove inner race.

Remove large cover - 4 -.
Remove head bevel gear with input shaft - 5 -.

Fig 10: Pulling Outer Race For Large Tapered Roller Bearing Off Large Cover Using Support, Internal Puller & Special Tool 3253/1

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Pull outer race for large tapered roller bearing off large cover.

A - Support , e.g. Kukko 22/4

B - Internal puller 56 - 110 mm , e.g. Kukko 21/89

Fig 11: Pressing Off Large Tapered Roller Bearing Inner Race From Head Bevel Gear Using Special Tools VW 412, 3253/1 & Separating Device

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Press off large tapered roller bearing inner race from head bevel gear.

A - Separating device 22 to 115 mm , e.g. Kukko 17/2

Fig 12: Removing Roller Sleeve From Final Drive Housing Using Special Tools VW 771, VW 771/15 & Internal Puller

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Remove roller sleeve from final drive housing.

A - Internal puller 22 to 28 mm , e.g. Kukko 21/4

Fig 13: Removing Sleeves For Oil Supply Using Support & Internal Pullers

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Remove sleeves for oil supply.

A - Support , e.g. Kukko 22/1

B - Internal puller 14.5 to 18.5 mm , e.g. Kukko 21/2

(to remove large sleeve)

C - Internal puller 8 to 12 mm , e.g. Kukko 21/02

(to remove small sleeve)

NOTE:

Removing is also possible when bevel gear transfer case is not disassembled.