00 general, technical datakankondemuamba.a.k.f.unblog.fr/files/2012/04/rear-differential.pdf ·...
TRANSCRIPT
REAR DIFFERENTIAL
Rear Final Drive
00 GENERAL, TECHNICAL DATA
DRIVETRAIN GUIDE
Fig. 1: Drivetrain Guide, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Transfer case
Transfer case, removing and installing --> Differential, removing and installing
2 - Drive shafts
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, September 20, 2009 9:03:57 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Drive shafts, removing and installing --> Driveshafts, removing and installing
3 - Rear final drive
Rear final drive, removing and installing --> Rear final drive, removing and installing
4 - Front final drive
Front final drive, removing and installing --> Front final drive, removing and installing
TRANSFER CASE IDENTIFICATION
Transfer case identification
The transfer case 0AD is allocated to the automatic transmission 09D.
Off-road reduction gearing is integrated into the transfer case.
Switching between street gearing "HIGH" and off-road gearing "LOW" is accomplished with the transfer case operating unit E473.
Code letters --> Code letters, transmission allocation, gear ratios, capacities.
Location on transfer case
Location on transfer case - arrow -
Fig. 2: Location On Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Code letters - arrow 1 - and date of manufacture - arrow 2 - of transfer case
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fig. 3: Code Letters And Date Of Manufacture Of Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Additional data depends on manufacture.
Code letters, transmission allocation, gear ratios, capacities
Example GJJ 03 05 02 I I I I I I I I Code letters Day Month Year (2002) of
manufacture
Transfer case 0ADCode letters FKA FKBApplication Model Touareg 2003 --> Touareg 2003 --> Engine 4.2 L - 228 kW 5.0 L -
230 kW Turbo-Diesel3.2 L -162 kW
Transmission housing extension length 127.4 mm 139.9 mmCapacities 0.85 liters
Transfer case 0ADCode letters FKC GFG GFHApplication Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 4.2 L - 228 kW 4.9
L - 230 kW Turbo-Diesel
3.2 L -162 kW
Transmission housing extension length 158.2 mm 127.4 mm 158.2 mmCapacities 0.85 liters
Transfer case OADCode letters GJJ GJK
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 3 © 2005 Mitchell Repair Information Company, LLC.
Application Model Touareg 2003 --> Touareg 2003 --> Engine 4.2 L - 228 kW 5.0 L -
230 kW Turbo-Diesel3.2 L -162 kW
Transmission housing extension length 127.4 mm 139.9 mmCapacities 0.85 liters
Transfer case 0ADCode letters GJL GTMApplication Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 5.0 L - 230 kW Turbo-
DieselTransmission housing extension length 158.2 mm 127.4 mmCapacities 0.85 liters
Transfer case 0ADCode letters GTN GTP HCHApplication Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2 L
- 177 kW3.2 L -162 kW 3.2 L - 177 kW
5.0 L - 230 kW Turbo-Diesel
Transmission housing extension length 139.9 mm 158.2 mm 127.4 mmCapacities 0.85 liters
Transfer case OADCode letters HPW HPXApplication Model Touareg 2003 --> Touareg 2003 --> Engine 5.0 L - 230 kW Turbo-
Diesel5.0 L - 230 kW Turbo-Diesel
Transmission housing extension length 127.4 mm 127.4 mmCapacities
Transfer case OADCode letters HMXApplication Model Touareg 2003 --> Engine 3.2 L -177 kWTransmission housing extension length 158.2 mmCapacities 0.85 liters
Transfer case 0ADCode letters HXB HXE HXAApplication Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 5.0 L - 230 kW 3.2 L -177 kW 4.2 L -228 kW 4.2 L
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 4 © 2005 Mitchell Repair Information Company, LLC.
FRONT FINAL DRIVE IDENTIFICATION
Front final drive identification
The front final drive 0AA is allocated to the automatic transmission 09D.
Code letters --> Code letters, transmission allocation, gear ratios, capacities.
Front final drive identification, location
Location on front final drive - arrow -.
Fig. 4: Location On Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Turbo-Diesel -257 kWTransmission housing extension length 127.4 mm 158.2 mm 127.4 mmCapacities 0.85 liters
Transfer case 0ADCode letters HXC FKFApplication Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -177 kW 3.2 L -177 kWTransmission housing extension length 139.9 mm 139.9 mmCapacities 0.85 liters
Transfer case 0ADCode letters FKG FKFApplication Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -177 kW 3.2 L -177 kWTransmission housing extension length 139.9 mm 139.9 mmCapacities 0.85 liters
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 5 © 2005 Mitchell Repair Information Company, LLC.
Code letters and date of manufacture of front final drive.
Fig. 5: Identifying Code Letters And Date Of Manufacture Of Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Additional data depends on manufacture.
Code letters, transmission allocation, gear ratios, capacities
Example FKK 20 08 02 I I I I I I I I Code letters Day Month Year (2002) of
manufacture
Front final drive 0AACode letters FKK FKM FKN
Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 4.2 L - 228 kW 3.2 L -162 kW 3.2 L
-177 kW4.2 L -228 kW
Gear ratio: Z 1 : Z 2 Final drive 37 : 10 = 3.700 39 : 10 = 3.900 41 :10 = 4.100
Capacities 1.0 litersDrive shaft flange dia. 114 mm 114 mm 114 mmElectromechanical differential lock Without Without Without
Front final drive 0AACode letters FKQ FLH FLJ
Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2 L
-177 kW3.2 L -162 kW 3.2 L -162 kW 3.2 L
-177 kWGear ratio: Z 1 : Z 2 Final drive 41 : 9 = 4.556 39 : 10 = 3.900 41 : 9 = 4.556
Capacities 1.0 liters
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 6 © 2005 Mitchell Repair Information Company, LLC.
Drive shaft flange dia. 114 mm 114 mm 114 mmElectromechanical differential lock Without With With
Front final drive 0AACode letters FVX FVZ GFA
Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 5.0 L - 230 kW
Turbo-Diesel4.2 L - 257 kW 5.0 L - 230 kW
Turbo-DieselGear ratio: Z 1 : Z 2 Final drive 36 : 11 = 3.273 43 : 10 = 4.300 36 : 11 = 3.273
Capacities 1.0 litersDrive shaft flange dia. 122 mm 114 mm 122 mmElectromechanical differential lock Without Without Without
Front final drive 0AACode letters GFB GLZ
Application Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2L - 177
kW5.0 L - 230 kW Turbo-Diesel
Gear ratio: Z 1 : Z 2 Final drive 41 : 9 = 4.556 36 : 11 = 3.273
Capacities 1.0 litersDrive shaft flange dia. 114 mm 122 mmElectromechanical differential lock Without Without
Front final drive 0AACode letters GMC GMN GNJ
Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2 L
-177 kW4.2 L -228 kW 4.9 L - 230 kW
Turbo-DieselGear ratio: Z 1 : Z 2 Final drive 41 : 9 = 4.556 41 : 9 = 4.556 36 : 11 = 3.273
Capacities 1.0 litersDrive shaft flange dia. 114 mm 122 mm 122 mmElectromechanical differential lock Without Without Without
Front final drive OAACode letters GNL GNM
Application Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L - 177 kW 4.5 L -
250 kW3.2 L -162 kW 3.2 L -177 kW
Gear ratio: Z 1 : Z 2 Final drive 41 : 10 = 4.100 41 : 9 = 4.556
Capacities 1.0 liters
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 7 © 2005 Mitchell Repair Information Company, LLC.
REAR FINAL DRIVE IDENTIFICATION
Rear final drive identification
The rear final drive 0AB/0AC is allocated to the automatic transmission 09D.
Code letters --> Code letters, transmission allocation, gear ratios, capacities.
Location on rear final drive
Location on rear final drive - arrow -.
Fig. 6: Location On Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Code letters and date of manufacture of rear final drive.
Drive shaft flange dia. 114 mm 114 mmElectromechanical differential lock Without Without
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 8 © 2005 Mitchell Repair Information Company, LLC.
Fig. 7: Code Letters And Date Of Manufacture Of Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Additional data depends on manufacture.
Code letters, transmission allocation, gear ratios, capacities
Example FKY 20 08 02 I I I I I I I I Code letters Day Month Year (2002) of
manufacture
Rear final drive 0AB/0ACCode letters FKS FKU FKV
Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 4.2 L -228 kW 3.2 L -162 kW 3.2 L
- 177 kW 3.2 L - 206 kW
4.2 L -228 kW
Gear ratio: Z 2 : Z 1 Final drive 37 : 10 = 3.700 39 : 10 = 3.900 41 : 10 = 4.100
Capacities 1.25 litersDrive shaft flange dia. 118 mm 112 mm 118 mmElectromechanical differential lock Without Without Without
Rear final drive 0AB/0ACCode letters FKW FLM
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 9 © 2005 Mitchell Repair Information Company, LLC.
Rear final drive "FWG" : In conjunction with automatic transmission 09D = drive axle flange dia. 112 mm.
Application Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -162 kW 3.2 L -162 kWGear ratio: Z 2 : Z 1 Final drive 41 : 9 = 4.556 39 : 10 = 3.900
Capacities 1.25 liters 1.6 litersDrive shaft flange dia. 112 mm 112 mmElectromechanical differential lock Without With
Rear final drive 0AB/0ACCode letters FLN FLP
Application Model Touareg 2003 --> Touareg 2003 --> Engine 4.2 L - 228 kW 3.2 L -162 kWGear ratio: Z 2 : Z 1 Final drive 41 : 10 = 4.100 41 : 9 = 4.556
Capacities 1.6 litersDrive shaft flange dia. 118 mm 112 mmElectromechanical differential lock With With
Rear final drive 0AB/0AC 0AB/0ACCode letters FLT FWC FWG
Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2 L - 177 kW 4.2
L -228 kW5.0 L - 230 kW Turbo-Diesel
4.2 L - 228 kW
Gear ratio: Z 2 : Z 1 Final drive 41 : 9 = 4.556 36 : 11 = 3.273 43 : 10 = 4.300
Capacities 1.6 liters 1.25 liters 1.6 litersDrive shaft flange dia. 118 mm 118 mm 112 mm/118 mmElectromechanical differential lock With Without With
Rear final drive 0AB/0ACCode letters FWH GFC GFD
Application Model Touareg 2004 --> Touareg 2004 --> Touareg 2004 --> Engine 5.0 L - 230 kW
Turbo-Diesel3.2 L -162 kW 5.0 L - 230 kW
Turbo-DieselGear ratio: Z 2 : Z 1 Final drive 36 : 11 = 3.273 41 : 9 = 4.556 36 : 11 = 3.273
Capacities 1.6 liters 1.25 liters 1.25 litersDrive shaft flange dia. 118 mm 112 mm 118 mmElectromechanical differential lock With Without Without
Rear final drive 0AB/0ACCode letters GLP
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 10 © 2005 Mitchell Repair Information Company, LLC.
Application Model Touareg 2004 --> Engine 3.2 L -162 kW 3.2 L -177 kWGear ratio: Z 2 : Z 1 Final drive 39 : 10 = 3.900
Capacities 1.25 litersDrive shaft flange dia. 112 mmElectromechanical differential lock Without
Rear final drive 0AB/0ACCode letters GLQ GLR GLS
Application Model Touareg 2004 --> Touareg 2004 --> Touareg 2004 --> Engine 4.2 L -228 kW 3.2 L -162 kW 3.2 L
-177 kW5.0 L - 230 kW Turbo-Diesel
Gear ratio: Z 2 : Z 1 Final drive 41 : 10 = 4.100 41 : 9 = 4.556 36 : 11 = 3.273
Capacities 1.25 litersDrive shaft flange dia. 118 mm 112 mm 118 mmElectromechanical differential lock Without Without Without
Rear final drive 0AB/0ACCode letters GMP GMQ
Application Model Touareg 2004 --> Touareg 2004 --> Engine 4.2 L -228 kW 4.2 L -228 kWGear ratio: Z 2 : Z 1 Final drive 41 : 9 = 4.556 41 : 9 = 4.556
Capacities 1.25 liters 1.6 litersDrive shaft flange dia. 118 mm 118 mmElectromechanical differential lock Without With
Rear final drive 0AB/0ACCode letters GNN HLQ
Application Model Touareg 2004 --> Touareg 2004 --> Engine 5.0 L - 230 kW Turbo-
Diesel5.0 L - 230 kW Turbo-Diesel
Gear ratio: Z 2 : Z 1 Final drive 36 : 11 = 3.273 36 : 11 = 3.273
Capacities 1.6 liters 1.6 litersDrive shaft flange dia. 118 mm 118 mmElectromechanical differential lock With With
Rear final drive 0AB/0ACCode letters HLU HLV
Application Model Touareg 2004 --> Touareg 2004 --> Engine 3.2 L -177 kW 4.2 L -228 3.2 L -162 kW 3.2 L -177
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 11 © 2005 Mitchell Repair Information Company, LLC.
kW kWGear ratio: Z 2 : Z 1 Final drive 41 : 09 = 4.556 41 : 09 = 4.556
Capacities 1.6 litersDrive shaft flange dia. 118 mm 112 mmElectromechanical differential lock With With
Rear final drive 0AB/0ACCode letters FLA GLV
Application Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -177 kW 3.2 L -177 kWGear ratio: Z 2 : Z 1 Final drive 41 : 09 = 4.556 41 : 09 = 4.556
Capacities 1.6 litersDrive shaft flange dia. 112 mm 112 mmElectromechanical differential lock Without Without
Rear final drive 0AB/0ACCode letters FLA JAJ GLV
Application Model Touareg 2003 --> Touareg 2003 --> Touareg 2003 --> Engine 3.2L - 177 kW 5.0 L - 230 kW
Turbo-Diesel3.2L - 177 kW
Gear ratio: Z 2 : Z 1 Final drive 41 : 09 = 4.556 41 : 09 = 4.556 41 : 09 = 4.556
Capacities 1.6 liters 1.6 liters 1.6 litersDriveshaft flange dia. 112 mm 114 mm 112 mmElectromechanical differential lock Without With Without
Rear final drive 0AB/0ACCode letters JLP JLQ
Application Model Touareg 2003 --> Touareg 2003 --> Engine 5.0 L - 230 kW Turbo-
Diesel5.0 L - 230 kW Turbo-Diesel
Gear ratio: Z 2 : Z 1 Final drive 36 : 11 = 3.272 36 : 11 = 3.272
Capacities 1.6 liters 1.6 litersDriveshaft flange 118 mm 118 mmElectromechanical differential lock Without With
Rear final drive 0AB/0ACCode letters JLP JLQ
Application Model Touareg 2003 --> Touareg 2003 --> Engine 5.0 L - 230 kW Turbo-
Diesel5.0 L - 230 kW Turbo-Diesel
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 12 © 2005 Mitchell Repair Information Company, LLC.
GENERAL REPAIR INSTRUCTIONS
General repair instructions
To ensure flawless and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. The usual basic safety precautions also, apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the article, are summarized here under the topic "Components" --> Components. They apply to this article.
Components
Transmission
When installing the transfer case, make sure that the alignment sleeves between the transmission and transfer case are correctly positioned.
When assembling mounting brackets as well as other waxed components the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.
When exchanging a transfer case, the gear oil must be filled up to lower edge of filler hole.
Capacities in transfer case --> Code letters, transmission allocation, gear ratios, capacities.
When exchanging a front final drive, the gear oil must be filled up to lower edge of filler hole.
Capacities in front final drive --> Code letters, transmission allocation, gear ratios, capacities.
When exchanging a rear final drive, the gear oil must be filled up to lower edge of filler hole.
Capacities in rear final drive --> Code letters, transmission allocation, gear ratios, capacities.
Gear ratio: Z 2 : Z 1 Final drive 36 : 11 = 3.272 36 : 11 = 3.272
Capacities 1.6 liters 1.6 litersDriveshaft flange dia. 118 mm 118 mmElectromechanical differential lock Without With
Rear final drive 0AB/0ACCode letters HEX JMB
Application Model Touareg 2003 --> Touareg 2003 --> Engine 3.2 L -177 kW 4.2 L -257 kWGear ratio: Z 2 : Z 1 Final drive 41 : 09 = 4.556 43 : 10 = 4.300
Capacities 1.6 liters 1.6 litersDriveshaft flange dia. 118 mm 118 mmElectromechanical differential lock With With
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 13 © 2005 Mitchell Repair Information Company, LLC.
Gaskets, seals
Replace O-rings.
Radial shaft seals.
Before installing:
Fig. 8: Identifying Space Between Oil Seal Sealing Lips Courtesy of VOLKSWAGEN UNITED STATES, INC.
Lightly lubricate outer edge and fill space between sealing lips - arrow - halfway with grease G 052 128 A1 .
After installation:
Check gear oil level in transfer case --> Gear oil level in transfer case, checking.
Check gear oil level in front final drive --> Gear oil in front final drive, checking.
Check gear oil level in rear final drive --> Gear oil in rear final drive, checking.
Locking elements
Replace circlip.
Do not overstretch circlips.
Circlips must be properly seated in the base of the groove.
Bolts and nuts
Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
The tightening torques stated apply to unoiled bolts and nuts.
Replace self-locking bolts and nuts.
Make sure with bolted connections that the contact surfaces as well as the visible surfaces of nuts and bolts are rewaxed after assembly, if necessary.
Use a thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be installed. Otherwise there is a risk that the bolts will shear the next time they are removed.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 14 © 2005 Mitchell Repair Information Company, LLC.
Bearings
Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
Guided fault finding, On Board Diagnostic (OBD) and measuring technology
Fig. 9: VAS 5051 Vehicle Diagnosis, Testing and Information System Courtesy of VOLKSWAGEN UNITED STATES, INC.
Before replacing the differential motor V253 of the transfer case and, on vehicles with differential lock on rear final drive, the differential lock motor V304 , the cause of the damage can likely be determined using the vehicle diagnostic, testing and information system VAS 5051 in the operating mode "Guided Fault-finding" , "On Board Diagnostics" and "Measuring technology".
34 CONTROLS, HOUSING
ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLED LOCATIONS FOR TRANSFER CASE
Electrical/electronic components and installed locations for transfer case
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 15 © 2005 Mitchell Repair Information Company, LLC.
Fig. 10: Electrical/Electronic Components And Installed Locations For Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Differential control module J646
Location --> Location of Differential control module J646
Removing and installing --> Differential control module J646 , removing and installing
2 - Transfer case operating unit E473
Location --> Location of transfer case operating unit E473
Removing and installing --> Location of transfer case operating unit E473
3 - Differential motor V253
Removing and installing --> Differential motor V253 , removing and installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 16 © 2005 Mitchell Repair Information Company, LLC.
The following components are integrated into the differential motor V253 :
Differential position sensor G398
Differential position sensor 2 G482
Motor temperature sensor G407
Brake for locking motor
4 - Data Link Connector (DLC)
Installed location --> Data Link Connector (DLC)
5 - Closed throttle position (CTP) switch F60
Only installed on vehicles with manual transmission
Installed location --> Location of closed throttle position (CTP) switch F60
Removing and installing --> Location of closed throttle position (CTP) switch F60
6 - Multi-function display in instrument cluster
Indicates condition and information about longitudinal lock and off-road gearing in transfer case
Location of Differential control module J646
Fig. 11: Location Of Differential Control Module J646 Courtesy of VOLKSWAGEN UNITED STATES, INC.
The differential control module J646 is located under the right front seat - arrow B -.
Differential control module J646 , removing and installing --> Differential control module J646 , removing and installing.
Location of transfer case operating unit E473
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 17 © 2005 Mitchell Repair Information Company, LLC.
Fig. 12: Location Of Transfer Case Operating Unit E473 Courtesy of VOLKSWAGEN UNITED STATES, INC.
The transfer case operating unit E473 - 1 - is located in shift cover - 2 - of center console.
Transfer case operating unit E473 , removing and installing --> 70 - INTERIOR TRIM .
Data Link Connector (DLC)
Fig. 13: Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.
The Data Link Connector (DLC) is located in the cover of the drivers side footwell.
Location of closed throttle position (CTP) switch F60
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 18 © 2005 Mitchell Repair Information Company, LLC.
Fig. 14: Location Of Closed Throttle Position (CTP) Switch F60 Courtesy of VOLKSWAGEN UNITED STATES, INC.
The closed throttle position (CTP) switch F60 - 1 - is located in the area of the shift cover with switching rockers on the manual transmission - 2 -.
Differential control module J646 , removing and installing
Removing
Remove right front seat --> 72 - SEAT - FRAMES .
If equipped, remove cover from seat frame.
First check whether a coded radio is installed. If this is the case obtain the anti-theft coding.
Switch ignition and all electrical consumers off, and remove ignition key.
Disconnect Ground (GND) terminal connector from battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
Fig. 15: Separating Connector At Differential Control Module J646 And Connector At Transmission Control Module J217 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Separate connector - 1 - at differential control module J646 and, if equipped, connector - 2 - at
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 19 © 2005 Mitchell Repair Information Company, LLC.
transmission control module J217.
Remove bolt - 3 -.
Pull the retainer with differential control module J646 in direction of - arrow - out of bracket on seat frame.
Fig. 16: Pressing Retaining Tabs And Pulling Differential Control Module J646 Out Of Retainer Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press retaining tabs - 1 - in direction of - arrow - and pull differential control module J646 out of retainer. Make sure that the differential control module J646 does not fall to floor.
Installing
Installation in reverse order of removal. Note the following:
Fig. 17: Pushing Retainer For Differential Control Module J646 With Latches Into Recesses Of Seat Frame Courtesy of VOLKSWAGEN UNITED STATES, INC.
Push retainer for differential control module J646 with latches - 2 - into recesses - 1 - of seat frame.
Fasten bolt - 3 - to 8 Nm.
Connect Ground (GND) terminal connector to battery and perform work sequences after connecting battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 20 © 2005 Mitchell Repair Information Company, LLC.
DIFFERENTIAL, REMOVING AND INSTALLING
Differential, removing and installing
Fig. 18: Identifying Special Tools - Differential, Removing And Installing (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Transmission support VW 785/1B
Adapter 10 - 222 A/7
Lifting tackle 2024 A
Thrust pad 3062
Transmission support 3282
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 21 © 2005 Mitchell Repair Information Company, LLC.
Adjustment plate 3282/37
Fig. 19: Identifying Special Tools - Differential, Removing And Installing (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383/A
Grease for clutch disc shaft splines G 000 100
Transfer case, removing
Raise vehicle.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 22 © 2005 Mitchell Repair Information Company, LLC.
Remove sound insulation on bottom of transmission.
If an underbody impact guard is located beneath the transfer case, remove it --> 50 - BODY - FRONT .
Remove rear section of exhaust system and, if necessary, catalytic converters (V10 TDI) -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Remove rear driveshaft --> Rear driveshaft, removing and installing.
Remove bolts for front driveshaft at front final drive and at transfer case.
Fig. 20: Removing Damper From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
If equipped with damper - A - , remove damper from transfer case (bolts - B -).
Before removing, mark the installation position of damper relative to transfer case. The text "TOP" - arrow - must point upward.
Set up engine/transmission jack V.A.G 1383/A with transmission support 3282 , adjustment plate 3282/37 for "0AD" transmission and support elements as follows:
Place adjustment plate 3282/37 on transmission support 3282 (adjustment plate only fits in one position).
Align arms of transmission support according to holes in adjustment plate.
The symbols on adjusting plate indicate the support elements required. The arrow points forward.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 23 © 2005 Mitchell Repair Information Company, LLC.
Fig. 21: Securing Transmission On Transmission Support 3282 Using Bolt & Removing Transmission Support From Structure Courtesy of VOLKSWAGEN UNITED STATES, INC.
Move engine/transmission jack V.A.G 1383/A with transmission support 3282 under transmission, align adjustment plate parallel to transmission and support transmission.
Secure transmission on transmission support 3282 using bolt - A -.
Remove transmission support - B - from structure.
Unbolt transmission support from transfer case console - arrows -.
Remove front driveshaft.
Remove side and lower transmission/transfer case bolts.
Fig. 22: Disconnecting Connector From Differential Motor Courtesy of VOLKSWAGEN UNITED STATES, INC.
Disconnect connector - A - and - B - from differential motor.
Lower engine and transmission assembly about 60 mm using engine/transmission jack V.A.G 1383/A.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 24 © 2005 Mitchell Repair Information Company, LLC.
Fig. 23: Securing Engine And Transmission Assembly On Structure With Transmission Support VW 785/1B Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure engine and transmission assembly on structure - arrows - with transmission support VW 785/1B as follows:
Lubricate contact surface of thrust pad of VW 785/1B with multi-purpose grease .
Place thrust plate 3062 on thrust pad. The smaller diameter of thrust plate 3062 faces toward thrust pad.
Place a piece of wood - A - between transmission and thrust pad 3062.
Fig. 24: Removing Upper Transfer Case/Transmission Bolts & Uncliping Breather Line From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove upper transfer case/transmission bolts - A -.
Remove - arrow 1 - and unclip - arrow 2 - breather line - B - from transfer case.
Press transfer case off from transmission.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 25 © 2005 Mitchell Repair Information Company, LLC.
Fig. 25: Lowering Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Lower transfer case.
Transfer case, transporting
Fig. 26: Attaching Engine Sling 2024A As Follows To Lifting Eyes Of Transfer Case And Transport With Workshop Crane Courtesy of VOLKSWAGEN UNITED STATES, INC.
Attach engine sling 2024A as follows to lifting eyes of transfer case and transport with workshop crane.
Input shaft side:
4. Hole for hook in position 1 of engine sling - arrow A -.
Output shaft side (driveshaft flange):
2. Hole for hook rail in position 8 of engine sling - arrow B -.
CAUTION: The hooks and locating pins must be secured with locking pins.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 26 © 2005 Mitchell Repair Information Company, LLC.
Transfer case, installing
Install in reverse order, paying attention to the following:
Check if alignment sleeves for centering the transmission/transfer case are installed in transmission; install if necessary.
Always replace O-ring seal between transfer case and transmission - arrow -. Lubricate lightly.
Fig. 27: Identifying O-Ring Seal Between Transfer Case And Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.
Lubricate transfer case input shaft and transmission output shaft with grease for clutch disc shaft splines G 000 100.
Push transfer case completely onto transmission, ensuring that transfer case input shaft splines are centered as they are guided onto transmission output shaft.
If splines are correctly positioned and centrally aligned, the transfer case will slide to stop against transmission.
Do not use bolts to pull transfer case onto the transmission, otherwise transfer case will be distorted.
Install front driveshaft --> Front driveshaft, removing and installing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 27 © 2005 Mitchell Repair Information Company, LLC.
Fig. 28: Removing/Installing Damper From/To Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
If equipped, install damper - A - to transfer case and fasten bolts - B -.
The text "TOP" - arrow - must point upward.
Install rear driveshaft --> Rear driveshaft, removing and installing.
If an underbody impact guard is located beneath the transfer case, install it --> 50 - BODY - FRONT .
Check gear oil level in transfer case --> Gear oil level in transfer case, checking.
Install exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Tightening torques
Console to transfer case, console to transmission and transmission support to structure.
Routing of breather line on transfer case
Transfer case to transmission 45 NmDamper to transfer case 32 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 28 © 2005 Mitchell Repair Information Company, LLC.
Fig. 29: Routing Of Breather Line On Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
The breather line - 1 - for the transfer case runs over the transfer case and manual transmission to coolant hose - 4 -.
The breather line is clipped into the retainer - 2 - on the transfer case and retainer - 3 - on the manual transmission.
The illustration shows routing of the line with a manual transmission. The routing of the line with an automatic transmission is similar.
TRANSMISSION CARRIER AND CONSOLE, REMOVING AND INSTALLING
Transmission carrier and console, removing and installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 29 © 2005 Mitchell Repair Information Company, LLC.
Fig. 30: Identifying Special Tools - Transmission Carrier And Console, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A with universal transmission adapter V.A.G 1359/2
Transmission carrier and console, removing
Raise vehicle.
Remove sound insulation below transmission.
If an underbody impact guard is located beneath transmission carrier and console, remove it --> 50 - BODY - FRONT .
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 30 © 2005 Mitchell Repair Information Company, LLC.
Fig. 31: Removing Bolts For Transmission Support From Transfer Case Console Courtesy of VOLKSWAGEN UNITED STATES, INC.
Place engine/transmission jack V.A.G 1383 A with universal adapter V.A.G 1359/2 and a block of wood - A - under transfer case.
Do not loosen bolts - arrows - yet.
Fig. 32: Unbolting/Tightening Transmission Carrier From/To Structure Courtesy of VOLKSWAGEN UNITED STATES, INC.
Unbolt transmission carrier - A - from structure - arrows -.
Lower transfer case slightly, until transmission carrier hangs freely.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 31 © 2005 Mitchell Repair Information Company, LLC.
Fig. 33: Removing Bolts For Transmission Support From Transfer Case Console Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove bolts for transmission support from transfer case console - arrows -.
Fig. 34: Unbolting Console From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Unbolt console - A - from transfer case - arrows -.
Transmission carrier and console, installing
Install is performed in the reverse order of removal.
Tightening torques
Due to the various engine variations and differing lengths of the transfer case extension, there are various consoles and transmission carriers. Allocation depends on the engine installed .
The various options result in the following fastening points for console to transfer case and transmission carrier
Console to transmission carrier
Always replace bolts
50 Nm plus an additional 90° (1 /4 turn
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 32 © 2005 Mitchell Repair Information Company, LLC.
to structure:
Vehicles with 6 and 8-cylinder engine.
Fig. 35: Identifying Fastening Points For Console To Transfer Case And Transmission Carrier To Structure (Vehicles With 6 And 8-Cylinder Engine) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Console to transmission carrier
*Always replace bolts
Vehicles 10-cylinder engine
Console to transfer case Bolts - 1 - M8 x 35 20 NmBolts - 2 - M8 x 70 20 Nm
Transmission carrier to structure
Always replace bolts
Bolts - 3 - M10 x 80 * See note 50 Nm plus an additional 90° 1 /4 turn
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 33 © 2005 Mitchell Repair Information Company, LLC.
Fig. 36: Identifying Fastening Points For Console To Transfer Case And Transmission Carrier To Structure (Vehicles 10-Cylinder Engine) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Console to transmission carrier
If an underbody impact guard is located beneath transmission carrier and console, install it --> 50 - BODY - FRONT .
BONDED RUBBER BUSHING IN TRANSMISSION CARRIER, REPLACING
Bonded rubber bushing in transmission carrier, replacing
Console to transfer case Bolts - 1 - M8 x 35 20 NmBolts - 2 - M8 x 70 20 Nm
Transmission carrier to structure
Always replace bolts
Bolts - 3 - M10 x 80 50 Nm plus an additional 90° 1 /4 turn
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 34 © 2005 Mitchell Repair Information Company, LLC.
Fig. 37: Identifying Special Tools - Bonded Rubber Bushing In Transmission Carrier, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Pressure plate VW 402
Punch VW 412
Thrust plate VW 432
Base block VW 441
Tube 3296
Alignment fixture T10214
Remove transmission carrier --> Transmission carrier and console, removing and installing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 35 © 2005 Mitchell Repair Information Company, LLC.
Fig. 38: Pressing Out Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pressing out bonded rubber bushing.
Fig. 39: Pressing New Bonded Rubber Bushing With Pressure Piece T10214/3 Into Guide Sleeve T10214/2 , Until Pressure Piece T10214/3 Is Flush With Guide Sleeve T10214/2 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Connect new bonded rubber bushing with pressure piece T10214/3.
Press new bonded rubber bushing - A - with pressure piece T10214/3 into guide sleeve T10214/2 , until pressure piece T10214/3 is flush with guide sleeve T10214/2.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 36 © 2005 Mitchell Repair Information Company, LLC.
Fig. 40: Aligning Bonded Rubber Bushing To Transmission Carrier, Using Assembly Tool T10214 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Align bonded rubber bushing to transmission carrier, using assembly tool T10214.
To align bushing, align bolts - A - and/or notch - arrow - on pressure piece T10214/3 centrally to holes in transmission carrier.
Spacing "x" must be equal.
Fig. 41: Pressing Bonded Rubber Bushing Into Transmission Carrier, Until Guide Sleeve T10214/2 Can Be Turned By Hand Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press bonded rubber bushing into transmission carrier, until guide sleeve T10214/2 can be turned by hand - arrows -.
Do not press the bonded rubber bushing any deeper into the transmission carrier than the height of the tube 3296. If necessary press further with base block VW 441 up to stop.
Install transmission carrier --> Transmission carrier and console, removing and installing.
GEAR OIL LEVEL IN TRANSFER CASE, CHECKING
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 37 © 2005 Mitchell Repair Information Company, LLC.
Gear oil level in transfer case, checking
Transmission oil specification --> Code letters, transmission allocation, gear ratios, capacities
Special tools, testers and auxiliary items required
Fig. 42: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Torque wrench V.A.G 1331
Fig. 43: Removing Sealing Plug For Gear Oil Inspection Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove sealing plug for gear oil inspection - arrow -.
Oil level is correct when the transfer case is filled up to lower edge of oil filler hole.
Insert new plug - arrow - and fasten.
When initially filling transfer case:
Remove plug - arrow -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 38 © 2005 Mitchell Repair Information Company, LLC.
Top off oil to lower edge of filler hole.
Insert new plug - arrow - and fasten.
SEALS FOR OUTPUT FLANGE/DRIVESHAFT AND DIFFERENTIAL MOTOR , REMOVING AND INSTALLING
Seals for output flange/driveshaft and differential motor , removing and installing
Fig. 44: Identifying Special Tools - Seals For Output Flange/Driveshaft And Differential Motor , Removing And Installing (1 Of 3) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Tightening torque: Oil filler plug 20 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 39 © 2005 Mitchell Repair Information Company, LLC.
Holding fixture VW 313
Pressure plate VW 402
Punch VW 408 A
Holding fixture VW 540
Slide hammer VW 771
Pulling hook VW 771/37
Fig. 45: Identifying Special Tools - Seals For Output Flange/Driveshaft And Differential Motor , Removing And Installing (2 Of 3) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Thrust pad 30 - 504
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 40 © 2005 Mitchell Repair Information Company, LLC.
Tube 32 - 119
Thrust pad 3062
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
- 3 - - Kukko 17/2 Separating device
Fig. 46: Identifying Special Tools - Seals For Output Flange/Driveshaft And Differential Motor , Removing And Installing (3 Of 3) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Thrust plate T10185
Thrust plate T10203
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 41 © 2005 Mitchell Repair Information Company, LLC.
Socket T10204
Wiring harness repair kit VAS 1978
Loctite 648
Tension transfer case in assembly fixture --> Secure transfer case to assembly stand with bolts
Fig. 47: Seals For Output Flange/Driveshaft And Differential Motor Remove/Install Components Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Nut, 130 Nm
Always replace
Removing --> Fig. 71
Installing --> Fig. 75
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 42 © 2005 Mitchell Repair Information Company, LLC.
Securing --> Fig. 69
Insert with Loctite 648
2 - O-ring
Always replace
Insert with gear oil --> Fig. 74
3 - Output flange
For rear driveshaft
Removing and installing --> Output flange oil seal for rear driveshaft, replacing (transfer case installed)
4 - Dust plate
For output flange
Pressing off --> Pressing off dust plate
Pressing on --> Pressing on dust plate to stop
5 - Seal
For output flange/rear driveshaft
Pulling out --> Pulling out oil seal for output flange/rear driveshaft
Driving in --> Driving in oil seal for output flange/rear driveshaft
Replacing with transmission installed --> Output flange oil seal for rear driveshaft, replacing (transfer case installed)
6 - Breather pipe
Removing Remove breather tube
Driving in --> Driving in breather tube
7 - Input shaft oil seal
Removing and installing --> Input shaft seal, replacing
8 - O-ring
Always replace
Insert into groove of input shaft --> Insert into O-ring into groove of input shaft
9 - Nut, 130 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 43 © 2005 Mitchell Repair Information Company, LLC.
Always replace
Removing --> Fig. 65
Installing --> Fig. 68
Securing --> Fig. 69
Insert with Loctite 648
10 - O-ring
Always replace
Insert with gear oil --> Fig. 74
11 - Output flange
For front driveshaft
Removing and installing --> Output flange oil seal for front driveshaft, replacing (transfer case installed)
12 - Dust plate
For output flange
Pressing off --> Pressing off dust plate
Pressing on --> Pressing on dust plate to stop
13 - Seal
For output flange/front driveshaft
Pulling out --> Pulling out oil seal for output flange/rear driveshaft
Driving in --> Driving in oil seal for output flange/front driveshaft
Replacing with transmission installed --> Output flange oil seal for front driveshaft, replacing (transfer case installed)
14 - O-ring
Must rest in groove of Differential Motor V253
15 - Alignment bushing
Qty. 2
For aligning differential motor on transfer case
16 - Differential motor V253
Removing and installing --> Differential motor V253 , removing and installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 44 © 2005 Mitchell Repair Information Company, LLC.
The following components are integrated into differential motor : Differential position sensor G398 , differential position sensor 2 G482 , Motor temperature sensor G407 , Brake for locking motor and Oil Temperature Sensor G8
Differential motor and integrated components can be tested with "Guided fault-finding"
17 - Bolt, 27 Nm
18 - Bolt, 14 Nm
19 - Clamp
For fastening differential motor V253 on transfer case
No longer available as separate part as of 02.05
20 - Oil drain plug, 20 Nm
Always replace
21 - Bolt, 20 Nm
22 - Bolt, 20 Nm
23 - Console
Removing and installing --> Transmission carrier and console, removing and installing
24 - Engine oil temperature sensor G8 , 17 Nm
On certain transmissions, a sealing plug may also be installed --> Repair solution for replacement of Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8
The discontinuation of engine oil temperature sensor occurred shortly after start of production. Transfer cases were introduced that were no longer equipped with a hole in the housing for the engine oil temperature sensor.
Repair solution for faulty engine oil temperature sensor --> Repair solution for replacement of Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8
25 - Seal
Always replace
26 - Oil filler plug, 20 Nm
Always replace
27 - Bolt, 32 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 45 © 2005 Mitchell Repair Information Company, LLC.
28 - Vibration damper
Not in all transmissions
Observe installed location --> Fig. 28
29 - Transfer case
Secure transfer case to assembly stand with bolts
Fig. 48: Securing Transfer Case To Assembly Stand With Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pressing off dust plate
Fig. 49: Pressing Off Dust Plate Courtesy of VOLKSWAGEN UNITED STATES, INC.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Pressing on dust plate to stop
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 46 © 2005 Mitchell Repair Information Company, LLC.
Fig. 50: Pressing On Dust Plate To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pulling out oil seal for output flange/rear driveshaft
Fig. 51: Pulling Out Sealing Ring Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Figure shows seal for output flange/rear driveshaft being pulled out.
The procedure for pulling out oil seal for output flange/front driveshaft is identical.
Driving in oil seal for output flange/rear driveshaft
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 47 © 2005 Mitchell Repair Information Company, LLC.
Fig. 52: Driving In Oil Seal For Output Flange/Rear Driveshaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Insert into O-ring into groove of input shaft
Fig. 53: Identifying O-Ring Seal Between Transfer Case And Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pressing on dust plate to stop
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 48 © 2005 Mitchell Repair Information Company, LLC.
Fig. 54: Pressing On Dust Plate To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Driving in oil seal for output flange/front driveshaft
Fig. 55: Driving New Seal In As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Remove breather tube
Fig. 56: Removing Breather Tube Courtesy of VOLKSWAGEN UNITED STATES, INC.
Guide 5 mm diameter drift - B - into hole of breather pipe.
Move breather pipe - A - in direction of arrow while simultaneously prying breather tube out of transfer case using screwdriver - C -.
Driving in breather tube
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 49 © 2005 Mitchell Repair Information Company, LLC.
Fig. 57: Driving In Breather Tube Courtesy of VOLKSWAGEN UNITED STATES, INC.
Coat breather tube with locking fluid Loctite 648 before driving in.
Repair solution for replacement of Differential Motor V253 and for malfunctioning Oil Temperature Sensor G8
Fig. 58: Repairing Solution For Replacement Of Differential Motor V253 And For Malfunctioning Oil Temperature Sensor G8 Courtesy of VOLKSWAGEN UNITED STATES, INC.
When replacing Differential Motor V253 and when Oil Temperature Sensor - 4 - is malfunctioning, the Oil Temperature Sensor (with sealing ring - 3 -) is replaced by a screw plug - 1 - with sealing ring - 2 -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 50 © 2005 Mitchell Repair Information Company, LLC.
Fig. 59: Removing Wiring Harness For Engine Oil Temperature Sensor G8 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Furthermore, the wiring harness for engine oil temperature sensor G8 is removed as follows:
Remove bolts - arrows - and remove retainer - 1 - for differential motor connector.
Pivot 10-pin connector out of retainer - 2 -.
Fig. 60: Identifying Engine Oil Temperature Sensor Wiring Harness & 10-Pin Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.
The wires, pins - 1 - and - 2 - of 10-pin connector must be removed using appropriate ejection tool from wiring harness repair kit VAS 1978.
Remove wiring harness - 3 - for engine oil temperature sensor.
Close off wire openings of terminals - 1 - and - 2 - in 10-pin connector .
Input shaft seal, replacing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 51 © 2005 Mitchell Repair Information Company, LLC.
Fig. 61: Identifying Special Tools - Input Shaft Seal, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Puller T10055
Adapter T10055/2
Thrust plate T10184
Sealing grease G 052 128 A1
Sheet metal screw approx. 4 mm diameter
Removing
Remove transfer case --> Transfer case, removing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 52 © 2005 Mitchell Repair Information Company, LLC.
Fig. 62: Screwing Sheet Metal Screw Into Seal Courtesy of VOLKSWAGEN UNITED STATES, INC.
To pull out seal, screw a sheet metal screw of approx. 4 mm diameter into seal - arrow -.
Thread in sheet metal screw in so that it jams between seal lip and metal ledge of sealing ring.
Do not screw in sheet metal screw too far to avoid damaging bearing behind it.
Pull out seal using puller T10055.
Installing
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Fig. 63: Driving New Seal In As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive new seal in as far as stop; be sure not to distort seal.
Install transfer case --> Transfer case, installing.
Check gear oil level in transfer case --> Gear oil level in transfer case, checking.
Output flange oil seal for front driveshaft, replacing (transfer case installed)
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:51 AM Page 53 © 2005 Mitchell Repair Information Company, LLC.
Fig. 64: Identifying Special Tools - Output Flange Oil Seal For Front Driveshaft, Replacing (Transfer Case Installed) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Slide hammer VW 771
Pulling hook VW 771/37
Handle-Hold Dr. Shaft Flange 3145
Torque wrench V.A.G 1332
Thrust plate T10185
Socket T10204
Sealing grease G 052 128 A1
Loctite 648
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 54 © 2005 Mitchell Repair Information Company, LLC.
2 Bolts M10 x 25
Removing
Remove front driveshaft --> Front driveshaft, removing and installing.
Fig. 65: Securing Handle-Hold Dr. Shaft Flange 3145 With Bolts To Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure Handle-Hold Dr. Shaft Flange 3145 with 2 bolts M10 x 25 to output flange - arrows -.
Unscrew nut for output flange.
Remove output flange.
Pull out sealing ring using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37.
Clean threads of nut.
Installing
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Fig. 66: Driving New Seal In As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 55 © 2005 Mitchell Repair Information Company, LLC.
Drive new seal in as far as stop; be sure not to distort seal.
Insert output flange.
Fig. 67: Moistening New O-Ring With Gear Oil And Insert Courtesy of VOLKSWAGEN UNITED STATES, INC.
Moisten new O-ring - arrow - with gear oil and insert.
Coat threads of new nut with locking fluid Loctite 648 .
Fig. 68: Tightening New Nut For Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Tighten new nut for output flange to torque specification.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 56 © 2005 Mitchell Repair Information Company, LLC.
Fig. 69: Securing Nut At Intended Points Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure nut at intended points - arrows - (e.g., using a drift).
The illustration shows securing the nut on output flange/rear driveshaft.
Install front driveshaft --> Front driveshaft, removing and installing.
Check gear oil level in transfer case --> Gear oil level in transfer case, checking.
Output flange oil seal for rear driveshaft, replacing (transfer case installed)
Tightening torque Nut for output flange on output shaft
Always replace nuts
130 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 57 © 2005 Mitchell Repair Information Company, LLC.
Fig. 70: Identifying Special Tools - Output Flange Oil Seal For Rear Driveshaft, Replacing (Transfer Case Installed) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Slide hammer VW 771
Pulling hook VW 771/37
Handle-Hold Dr. Shaft Flange 3145
Torque wrench V.A.G 1332
Thrust plate T10185
Socket T10204
Sealing grease G 052 128 A1
Loctite 648
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 58 © 2005 Mitchell Repair Information Company, LLC.
2 Bolts M10 x 25
Removing
Remove rear driveshaft --> Rear driveshaft, removing and installing.
Fig. 71: Unscrewing Nut For Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Unscrew nut for output flange.
A - Bolts M10 x 30 with nuts
Remove output flange.
Fig. 72: Pulling Out Sealing Ring Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out sealing ring using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37.
Clean threads of nut.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 59 © 2005 Mitchell Repair Information Company, LLC.
Installing
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.
Fig. 73: Driving New Seal In As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive new seal in as far as the stop; be sure not to distort seal.
Insert output flange.
Fig. 74: Moistening New O-Ring With Gear Oil And Insert Courtesy of VOLKSWAGEN UNITED STATES, INC.
Moisten new O-ring - arrow - with gear oil and insert.
The figure shows the O-ring on output flange/front driveshaft.
Coat threads of new nut with locking fluid Loctite 648.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 60 © 2005 Mitchell Repair Information Company, LLC.
Fig. 75: Unscrewing/Tightening Nut For Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Tighten new nut for output flange to torque specification.
Fig. 76: Securing Nut At Intended Points Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure nut at intended points - arrows - (e.g., with a drift).
Install rear driveshaft --> Rear driveshaft, removing and installing.
Check gear oil level in transfer case --> Gear oil level in transfer case, checking.
DIFFERENTIAL MOTOR V253 , REMOVING AND INSTALLING
Differential motor V253 , removing and installing
Special tools, testers and auxiliary items required
Tightening torque Nut for output flange on output shaft
Always replace nut
130 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 61 © 2005 Mitchell Repair Information Company, LLC.
Fig. 77: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Torque wrench V.A.G 1331
Differential motor V253 , removing
If Differential Motor V253 is replaced, observe the following:
The new Differential Motor is set to a specified position.
To make installation easier, set this position on differential as well, if possible:
Fig. 78: Rotating Transfer Case Operating Unit E473 To "LOW" Position Courtesy of VOLKSWAGEN UNITED STATES, INC.
To do this, switch ignition on.
Rotate Transfer Case Operating Unit E473 to "LOW" position - arrow -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 62 © 2005 Mitchell Repair Information Company, LLC.
Then switch ignition off.
If previous Differential Motor will be reinstalled, Transfer Case Operating Unit E473 does not need to be set to the "LOW" position.
Continued for all
If shield is installed over differential motor , remove it.
Fig. 79: Installing Bracket & Connecting Connectors Courtesy of VOLKSWAGEN UNITED STATES, INC.
Separate connectors - A - , - B - and - C -.
Remove bracket - D - - arrows -.
Fig. 80: Removing Bolts And Differential Motor From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 63 © 2005 Mitchell Repair Information Company, LLC.
Remove bolts - arrows - and remove differential motor from transfer case.
Differential motor V253 , installing
If a new Differential Motor is installed, observe the following:
(Fig. 1)
Fig. 81: Identifying Transfer Case Operating Unit E473 Is In "LOW" Position Courtesy of VOLKSWAGEN UNITED STATES, INC.
The Transfer Case Operating Unit E473 is in "LOW" position.
Shaft with interrupted tooth pattern - 1 - must be in - a - position.
" a = approx. 10° "
Transfer Case Operating Unit E473 was already turned to "LOW" position with ignition on.
Transfer Case Operating Unit setting --> (Fig. 1)
Transfer Case Operating Unit E473 was not turned to "LOW" position.
Transfer Case Operating Unit setting --> (Fig. 2)
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 64 © 2005 Mitchell Repair Information Company, LLC.
If necessary, set the interrupted tooth pattern - 1 - on shaft of differential motor to position shown in the illustration (e.g. using a screwdriver).
(Fig. 2)
Fig. 82: Identifying Transfer Case Operating Unit E473 Is Not In "LOW" Position Courtesy of VOLKSWAGEN UNITED STATES, INC.
The Transfer Case Operating Unit E473 is not in "LOW" position.
Shaft with interrupted tooth pattern - 1 - must be in - a - position.
" a = approx. 60° "
If necessary, set the interrupted tooth pattern - 1 - on shaft of differential motor to the position shown in the illustration (e.g. using a screwdriver).
Continued for all
Make sure that O-ring that seals on transfer case makes contact in base of groove at the differential motor.
Set differential motor on alignment sleeves - 2 - of transfer case.
Ensure that the interrupted teeth on differential motor - arrow A - and on selector shaft/transfer case - arrow B - are aligned.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 65 © 2005 Mitchell Repair Information Company, LLC.
Fig. 83: Removing/Installing Bolts And Differential Motor From Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Insert bolts - arrows - for differential motor and fasten.
Fig. 84: Installing Bracket & Connecting Connectors Courtesy of VOLKSWAGEN UNITED STATES, INC.
Install bracket - D - - arrows -.
Connect connectors - A - , - B - and - C -.
If shield was fitted over differential motor , install it.
Check gear oil level in transfer case --> Gear oil level in transfer case, checking.
Tightening torque Differential motor to transfer case 27 NmBracket for transfer case 14 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 66 © 2005 Mitchell Repair Information Company, LLC.
39 FINAL DRIVE, DRIVESHAFTS
DRIVESHAFTS, REMOVING AND INSTALLING
Assembly overview
Front driveshaft, removing and installing --> Front driveshaft, removing and installing.
Rear driveshaft, removing and installing --> Rear driveshaft, removing and installing.
No repairs may be performed on the driveshafts.
Do not flex rear driveshaft; store and transport extended.
Store rear driveshaft with bracket facing upward.
Before removing, mark the positions of all parts in relation to each other. Re-install in the same position otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises.
If front or rear driveshaft is disconnected only from transfer case or only from its respective final drive, it must be tied up or supported.
In customer complaints arise (noises, vibration) regarding the front or rear driveshaft, turn respective driveshaft on the final drive the distance of one bolt hole before bolting on again. This procedure can be repeated 5 times on the final drives and twice on back of transfer case.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 67 © 2005 Mitchell Repair Information Company, LLC.
Fig. 85: Driveshafts Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Front final drive
Colored markings on driveshaft flange and on front driveshaft must line up.
2 - Lock plate
3 - Bolt, 30 Nm plus an additional 90° 1 /4 turn
Always replace
4 - Front driveshaft
Installation position: Colored spot on front driveshaft must line up with colored spot on front final drive
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 68 © 2005 Mitchell Repair Information Company, LLC.
5 - Transfer case
6 - Nut
Always replace
7 - Flexible disc
Removing and installing --> Flexible disc, removing and installing
8 - Washer
9 - Bolt, 75 Nm
10 - Rear driveshaft
Installation position: Colored spot on rear driveshaft must line up with colored spot on rear final drive
To avoid damaging boot in vicinity of center bearing - arrow - , rear driveshaft may only be flexed slightly
11 - Multi-point socket head bolt, 30 Nm plus an additional 90° 1 /4 turn
Always replace
12 - Lock plate
13 - Rear final drive
14 - Bracket
For center bearing
15 - Bolt, 20 Nm
On bracket for rear driveshaft
To adjust driveshaft center bearing free of tension, loosen and tighten --> Rear driveshaft center bearing, installing stress-free
16 - Bolt, 60 Nm
Bracket to body
17 - Bolt
18 - Hex nut, 75 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 69 © 2005 Mitchell Repair Information Company, LLC.
Always replace
Front driveshaft, removing and installing
Fig. 86: Identifying Special Tools - Front Driveshaft, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2
Brake pedal loading device V.A.G 1869/2
A twin-post vehicle hoist should be used when working on the front driveshaft.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 70 © 2005 Mitchell Repair Information Company, LLC.
Before removing, mark the positions of all parts in relation to each other. Re-install in the same position otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises.
If droning noises occur when driving, unbolt front driveshaft from flange at front final drive, rotate one hole relative to flange and bolt on again.
If droning noises are still audible, the front driveshaft can be rotated one hole relative to flange a total of 5 times.
Removing
For vehicles with automatic transmission, select position "N" with selector lever.
Insert brake pedal depressor V.A.G 1869/2.
Raise vehicle.
Remove sound insulation on bottom of transmission.
If an underbody impact guard is located beneath the driveshaft, remove it --> 50 - BODY - FRONT .
Fig. 87: Identifying Mark On Driveshaft Flange & Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Check whether there is a colored marking on front driveshaft and at driveshaft flange at front final drive.
If this marking is not present, then mark in color the position of driveshaft flange - arrow A - to front final drive - arrow B -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 71 © 2005 Mitchell Repair Information Company, LLC.
Fig. 88: Removing Lower Three Bolts From Front Driveshaft At Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove lower three bolts from front driveshaft at front final drive - arrows A -.
Fig. 89: Removing Lower Three Bolts From Front Driveshaft At Output Flange Of Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove lower three bolts from front driveshaft at output flange of transfer case - arrows B -.
Lower vehicle.
Remove brake pedal depressor V.A.G 1869/2.
Raise vehicle.
Rotate both front wheels in same direction at same time so that the front driveshaft rotates 1 /2 turn
(180°).
Lower vehicle.
Insert brake pedal depressor V.A.G 1869/2.
Raise vehicle.
Remove remaining three bolts from front driveshaft at front final drive and at transfer case.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 72 © 2005 Mitchell Repair Information Company, LLC.
Fig. 90: Placing Engine/Transmission Jack V.A.G 1383 A With Universal Adapter 1359/2 And Block Of Wood Under Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove transmission carrier as follows:
Place engine/transmission jack V.A.G 1383 A with universal adapter 1359/2 and a block of wood - A - under transfer case.
Do not loosen bolts - arrows - yet.
Fig. 91: Unbolting/Tightening Transmission Carrier From/To Structure Courtesy of VOLKSWAGEN UNITED STATES, INC.
Unbolt transmission carrier - A - from structure - arrows -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 73 © 2005 Mitchell Repair Information Company, LLC.
Fig. 92: Removing Bolts For Transmission Support From Transfer Case Console Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove bolt for transmission carrier from transfer case console - arrows -.
Remove front driveshaft.
If the front driveshaft cannot be removed, lower the engine/transmission assembly slightly. When doing this, the engine must not come to rest against the bulkhead.
Installing
Installation is in reverse order of removal. Note the following:
Fig. 93: Identifying Mark On Driveshaft Flange & Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Always replace bolts for front driveshaft.
Markings - arrow A - and - arrow B - must line up as much as possible.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 74 © 2005 Mitchell Repair Information Company, LLC.
Fig. 94: Removing Bolts For Transmission Support From Transfer Case Console Courtesy of VOLKSWAGEN UNITED STATES, INC.
Install transmission carrier as follows:
Use new bolts.
First tighten the transmission carrier to the transfer case console - arrows - to tightening torque.
Fig. 95: Unbolting/Tightening Transmission Carrier From/To Structure Courtesy of VOLKSWAGEN UNITED STATES, INC.
Then, tighten the transmission carrier - A - to the body - arrows - to tightening torque --> Tightening torques.
Insert bolts for front driveshaft and tighten to tightening torque --> Tightening torques
If an underbody impact guard is located beneath the driveshaft, install it --> 50 - BODY - FRONT .
Tightening torques Console to transmission carrier
Always replace bolts
50 Nm plus an additional 90° 1 /4 turn
Transmission carrier to structure 50 Nm plus an additional 90° 1 /4 turn
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 75 © 2005 Mitchell Repair Information Company, LLC.
Rear driveshaft, removing and installing
Fig. 96: Identifying Special Tools - Rear Driveshaft, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Always replace bolts Front driveshaft to front final drive flange
Always replace bolts
30 Nm plus an additional 90° 1 /4 turn
Front driveshaft to transfer case flange
Always replace bolts
30 Nm plus an additional 90° 1 /4 turn
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 76 © 2005 Mitchell Repair Information Company, LLC.
Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2
Brake pedal loading device V.A.G 1869/2
A twin-post vehicle hoist should be used when working on the rear driveshaft.
Before removing, mark the positions of all parts in relation to each other. Re-install in the same position otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises.
If droning noises occur when driving, unbolt rear driveshaft from flange at rear final drive, rotate one hole relative to flange and bolt on again.
If droning noises are still audible, rear driveshaft can be rotated one hole relative to flange a total of 5 times at rear final drive and a total of 2 times at transfer case.
Do not flex rear driveshaft; store only extended with center bearing bracket facing upward.
Removing
For vehicles with automatic transmission, select position "N" with selector lever.
Insert brake pedal depressor V.A.G 1869/2.
Raise vehicle.
Remove rear part of exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
If an underbody impact guard is located beneath the driveshaft, remove it --> 50 - BODY - FRONT .
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 77 © 2005 Mitchell Repair Information Company, LLC.
Fig. 97: Identifying Mark On Driveshaft Flange & Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Check whether there is a colored marking on rear driveshaft and on driveshaft flange at rear final drive.
If marking is not present, mark in color position of driveshaft flange - arrow A - to rear final drive - arrow B -.
Fig. 98: Marking Position Of Rear Driveshaft To Transfer Case Output Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Mark position of rear driveshaft to transfer case output flange - arrow -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 78 © 2005 Mitchell Repair Information Company, LLC.
Fig. 99: Removing Lower Bolts For Rear Driveshaft At Rear Final DriveCourtesy of VOLKSWAGEN UNITED STATES, INC.
Remove lower 3 bolts for rear driveshaft at rear final drive.
Lower vehicle.
Remove brake pedal depressor V.A.G 1869/2.
Raise vehicle.
Rotate both rear wheels in same direction at the same time so that the rear driveshaft rotates 1 /2 turn
(180°).
Lower vehicle.
Insert brake pedal depressor V.A.G 1869/2.
Raise vehicle.
Remove remaining 3 bolts for rear driveshaft at rear final drive.
Fig. 100: Removing Bolts From Rear Driveshaft At Transfer Case Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove bolts - arrows - from rear driveshaft at transfer case. For this, counterhold nuts with an open end wrench.
Place engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2 under subframe/rear axle.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 79 © 2005 Mitchell Repair Information Company, LLC.
Fig. 101: Removing/Installing Both Front Bolts On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Support subframe with a wooden block --> Fig. 102.
Remove both front bolts - arrows - on subframe.
Fig. 102: Lowering Subframe Using Engine/Transmission Jack V.A.G 1383 A Courtesy of VOLKSWAGEN UNITED STATES, INC.
Lower subframe using engine/transmission jack V.A.G 1383 A by dimension - a - = 50 mm.
1 - Wooden support
To avoid damaging rear driveshaft, have a second technician assist in removing rear driveshaft.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 80 © 2005 Mitchell Repair Information Company, LLC.
Fig. 103: Loosening Bolts For Center Bearing Bracket & Unbolting Center Bearing Bracket From BodyCourtesy of VOLKSWAGEN UNITED STATES, INC.
Loosen bolts - arrows B - for center bearing bracket by approx. 2 turns.
Unbolt center bearing bracket from body - arrows A -.
Fig. 104: Pressing Rear Driveshaft Off Of Rear Final Drive And Pivot It Over Final Drive Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press rear driveshaft - 1 - off of rear final drive - 2 - and pivot it over final drive flange.
Carefully pull rear driveshaft off from alignment sleeves of output flange/transfer case.
Remove rear driveshaft.
Set aside rear driveshaft with center bearing bracket facing upward.
Installing
Installation is in reverse order of removal. Note the following:
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 81 © 2005 Mitchell Repair Information Company, LLC.
Fig. 105: Identifying Mark On Driveshaft Flange & Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Always replace bolts for rear driveshaft.
Markings - arrow A - and - arrow B - must line up as much as possible.
Fig. 106: Identifying Seal In Rear Driveshaft Flange At Flange/Transfer Case Must Not Be Damaged When Removing/Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Seal - arrow - in rear driveshaft flange at flange/transfer case must not be damaged when removing and installing.
Replace rear driveshaft if damaged.
Do not tip rear driveshaft; push horizontally onto guide shaft.
After loosening a rear driveshaft flange, install center bearing so that it is free of stress --> Rear driveshaft center bearing, installing stress-free.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 82 © 2005 Mitchell Repair Information Company, LLC.
Fig. 107: Removing/Installing Both Front Bolts On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Install and fasten bolts - arrows - at subframe --> 42 - REAR SUSPENSION
After installing rear driveshaft, install center bearing so that it is free of stress --> Rear driveshaft center bearing, installing stress-free.
Install rear part of exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Insert bolts for rear driveshaft and tighten to specified torque.
If an underbody impact guard is located beneath the driveshaft, install it --> 50 - BODY - FRONT .
Rear driveshaft center bearing, installing stress-free
Tightening torques Rear driveshaft to rear final drive flange
Always replace bolts
30 Nm plus an additional 90° 1 /4 turn
Rear driveshaft to flexible disc
Always replace bolts
75 Nm
Center bearing bracket to body 60 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 83 © 2005 Mitchell Repair Information Company, LLC.
If necessary, remove rear part of exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Fig. 108: Loosening Bolts For Center Bearing Bracket & Unbolting Center Bearing Bracket From BodyCourtesy of VOLKSWAGEN UNITED STATES, INC.
Remove bolts - arrows B -.
Loosen bolts - arrows A - several turns.
Fig. 109: Aligning Center Bearing Bracket Centrally To Lateral Stops On Body Courtesy of VOLKSWAGEN UNITED STATES, INC.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 84 © 2005 Mitchell Repair Information Company, LLC.
Align center bearing bracket centrally to lateral stops - arrows - on body.
Fix center bearing bracket in place by fastening the two bolts - A -.
Check if threaded holes of center bearing - B - are lined up with slots of bracket.
For slight deviations:
Move center bearing bracket laterally until the threaded holes and slots line up.
When moving bracket, make sure that the center bearing does not touch the body (driveshaft tunnel).
For larger deviations or if clearance between center bearing and body is minimal:
Fig. 110: Unbolting/Tightening Transmission Carrier From/To Structure Courtesy of VOLKSWAGEN UNITED STATES, INC.
Loosen bolts - arrows - for transmission carrier by approx. 3 turns.
Move transmission laterally until threaded holes of center bearing and slots of center bearing bracket line up.
When moving transmission, make sure that the center bearing does not touch body (driveshaft tunnel).
Replace individual bolts - arrows - , in succession, for transmission carrier and tighten them to tightening torque.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 85 © 2005 Mitchell Repair Information Company, LLC.
Fig. 111: Loosening Bolts For Center Bearing Bracket & Unbolting Center Bearing Bracket From BodyCourtesy of VOLKSWAGEN UNITED STATES, INC.
Install bolts - arrows B - and fasten bolts - arrows A - and - arrows B -.
If removed earlier, install rear part of exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Flexible disc, removing and installing
Special tools, testers and auxiliary items required
Torque specifications Center bearing bracket to body 60 NmRear driveshaft center bearing to bracket 20 NmTransmission carrier to structure
Always replace bolts
50 Nm plus an additional 90° 1 /4
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 86 © 2005 Mitchell Repair Information Company, LLC.
Fig. 112: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Fig. 113: Brake Pedal Depressor V.A.G 1869/2 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Brake pedal loading device V.A.G 1869/2
A twin-post vehicle hoist should be used when working on the rear driveshaft.
Before removing, mark the positions of all parts in relation to each other. Re-install in the same position otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises.
Do not flex rear driveshaft; store only extended with center bearing bracket facing upward.
Removing
For vehicles with automatic transmission, select position "N" with the selector lever.
Insert brake pedal depressor V.A.G 1869/2.
Raise vehicle.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 87 © 2005 Mitchell Repair Information Company, LLC.
Remove rear part of exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Remove rear driveshaft --> Rear driveshaft, removing and installing.
Fig. 114: Unbolting Flexible Disc From Rear Driveshaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Unbolt flexible disc from rear driveshaft - arrows -.
Installing
Install in reverse order, paying attention to the following:
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 88 © 2005 Mitchell Repair Information Company, LLC.
Fig. 115: Identifying Seal In Rear Driveshaft Flange At Flange/Transfer Case Must Not Be Damaged When Removing/Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Seal - arrow - in rear driveshaft flange at flange/transfer case must not be damaged when removing and installing.
Replace rear driveshaft if damaged.
Do not tip rear driveshaft; push horizontally onto guide shaft.
Install rear driveshaft --> Rear driveshaft, removing and installing.
After installing rear driveshaft, install center bearing so that it is free of stress --> Rear driveshaft center bearing, installing stress-free.
Install rear part of exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Tightening torque Flexible disc to transfer case flange
Always replace nut, build torque at the bolt while counterholding the nut
75 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 89 © 2005 Mitchell Repair Information Company, LLC.
39F FINAL DRIVE, FRONT DIFFERENTIAL
GEAR OIL IN FRONT FINAL DRIVE, CHECKING
Transmission oil specification --> Code letters, transmission allocation, gear ratios, capacities
Special tools, testers and auxiliary items required
Fig. 116: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Torque wrench V.A.G 1331
Fig. 117: Removing Sealing Plug For Gear Oil Inspection Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove sealing plug for gear oil inspection - arrow -.
Oil level is correct when the front final drive is filled up to lower edge of oil filler hole.
Fasten bolt - arrow - with new seal.
When initially filling front final drive
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 90 © 2005 Mitchell Repair Information Company, LLC.
Remove bolt - arrow -.
Top off oil to lower edge of filler hole.
Fasten bolt - arrow - with new seal.
FRONT FINAL DRIVE, REMOVING AND INSTALLING
Front final drive, removing and installing
Fig. 118: Identifying Special Tools - Front Final Drive, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Tightening torque Oil filler plug to front final drive 35 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 91 © 2005 Mitchell Repair Information Company, LLC.
Tensioner hooks VW 552
Spindle 10 - 222 A/11
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2
Socket insert T10099/1
Front final drive, removing
Loosen wheel bolts.
Raise vehicle.
Remove front wheels.
Remove left front and right wheel housing liners --> 68 - INTERIOR EQUIPMENT .
Fig. 119: Hooking In Tensioner Hooks VW552 On Both Vehicles Sides In Upper Opening Of Wheel Housing And In Upper Control Arm Courtesy of VOLKSWAGEN UNITED STATES, INC.
If equipped with air spring struts, the air line connection - 1 - must be loosened and allow air to escape. Then, tighten connection to specified torque --> 40 - FRONT SUSPENSION .
Hook tensioner hooks VW 552 onto each side of vehicle in upper openings of wheel housing - arrow A - and in upper control arms - arrow B -.
Pretension control arm slightly so that ball joint pin of control arm will not be damaged.
Remove sound insulation below engine/transmission.
If an underbody impact guard is located beneath the front final drive, remove it --> 50 - BODY - FRONT .
Remove sound insulation retainer.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 92 © 2005 Mitchell Repair Information Company, LLC.
Fig. 120: Removing/Installing Shield From Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove shield from front final drive - arrows -.
Fig. 121: Removing Lower Three Bolts From Front Driveshaft At Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Disconnect driveshaft from front final drive - arrows A - and tie up --> Front driveshaft, removing and installing.
Unbolt left and right drive axles. To loosen bolts, use socket insert T10099/1 if necessary.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 93 © 2005 Mitchell Repair Information Company, LLC.
Fig. 122: Identifying Universal Joint Bolt And Heat ShieldCourtesy of VOLKSWAGEN UNITED STATES, INC.
If equipped, remove shield - A - from steering gear (2 bolts).
Remove bolt - B - for universal joint on steering gear and pull universal joint from steering gear.
Fig. 123: Identifying Coolant Pipes, Nut & Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.
If equipped, remove coolant pipes - 1 - from left longitudinal member. When doing this, remove nut - A - and bracket - arrow B -.
Fig. 124: Hooking Spindles 10 - 222 A/11 In Eyelets Of Engine Carrier On Left/Right Vehicle Sides Courtesy of VOLKSWAGEN UNITED STATES, INC.
Hook spindles 10 - 222 A/11 in eyes - arrow - of subframe on left and right sides of vehicle.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 94 © 2005 Mitchell Repair Information Company, LLC.
Fig. 125: Setting Wooden Block Into Hanger Of Each Spindle 10 - 222 A/11 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Set a wooden block - A - approx. 300 mm long into the hanger of each spindle 10 - 222 A/11.
Hangers must face toward the rear.
Tighten winged nuts of spindles , ensuring that wooden blocks lie against subframe - B -.
Place insert from a trolley jack into engine/transmission jack V.A.G 1383 A.
Fig. 126: Placing Engine/Transmission Jack V.A.G 1383 A Under Engine Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC.
Place engine/transmission jack V.A.G 1383 A under subframe and lightly press against it.
A - Wooden support
Remove one of the subframe mounting bolts - arrows -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 95 © 2005 Mitchell Repair Information Company, LLC.
Fig. 127: Checking Inner Contour Of Sleeve In Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Check inner contour of sleeve - arrow - in bonded rubber bushing.
Remove mounting bolts for subframe from body - arrows - in Fig. 128.
Fig. 128: Removing/Installing Coupling Rods On Left/Right From Stabilizer Bar Courtesy of VOLKSWAGEN UNITED STATES, INC.
Disconnect left and right - 1 - coupling rods from stabilizer bar.
Remove threaded connection from air spring strut or suspension strut to lower control arm. The subframe must be lowered via the spindles 10 - 222 A/11 by approx. 50 mm direction of - arrow - to remove bolt - 2 -.
Inner contour of sleeve Rectangular Subframe cannot be secured.
Mark position of subframe on body using a felt tip pen.
Round Secure subframe before removal --> 40 - FRONT SUSPENSION
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 96 © 2005 Mitchell Repair Information Company, LLC.
Use bolts - 2 - with additional washers, or bolts M14 x 1.5 approx. 90 mm long, to secure subframe to body on left and right - 3 -.
Remove engine/transmission jack V.A.G 1383 A from under subframe.
Fig. 129: Placing Engine/Transmission Jack V.A.G 1383 A With Universal Transmission Adapter 1359/2 Under Subframe And Lightly Press Against It Courtesy of VOLKSWAGEN UNITED STATES, INC.
Place engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2 under subframe and lightly press against it. When doing this, place wooden block - A - underneath subframe and - B - under front final drive.
Secure subframe with belt from universal transmission adapter V.A.G 1359/2.
Remove spindles 10 - 222 A/11 from subframe.
Fig. 130: Pulling/Pushing Breather Line With Connecting Nipple Carefully Off Of Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull breather line - A - with connecting nipple - arrow - carefully off of front final drive.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 97 © 2005 Mitchell Repair Information Company, LLC.
Fig. 131: Measuring Dimension Between Body And Fastening Surface Of Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Carefully lower subframe with front final drive to dimension - a - , approx 200 mm.
Measure dimension - a - between body and fastening surface of subframe.
Fig. 132: Removing/Installing Bolts With Nuts For Front Final Drive On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove bolts with nuts - 1 - through - 3 - for front final drive - A - on subframe - B -.
A second technician is required to remove front final drive.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 98 © 2005 Mitchell Repair Information Company, LLC.
Fig. 133: Removing Front Final Drive Rearward Between Subframe And Engine/Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove front final drive - 1 - rearward between subframe and engine/transmission as follows:
Tie up left drive axle.
Have second technician remove front final drive from supports in subframe.
Guide right drive axle out of flange shaft.
Raise front final drive over steering gear and guide out toward rear.
Front final drive, installing
Install in reverse order, paying attention to the following:
Always replace bolts for front driveshaft.
A second technician is required to insert front final drive into subframe supports.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 99 © 2005 Mitchell Repair Information Company, LLC.
Fig. 134: Removing/Installing Bolts With Nuts For Front Final Drive On Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Install bolts with nuts - 1 - through - 3 - for front final drive - A - on subframe - B - --> 40 - FRONT SUSPENSION .
Raise subframe using transmission jack.
Fig. 135: Pulling/Pushing Breather Line With Connecting Nipple Carefully Off Of Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Push breather line - A - with connecting nipple - arrow - carefully into front final drive. When doing so, connecting nipple must be stand vertical and be inserted between raised areas of the housing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 100 © 2005 Mitchell Repair Information Company, LLC.
Fig. 136: Hooking Spindles 10 - 222 A/11 In Eyelets Of Engine Carrier On Left/Right Vehicle Sides Courtesy of VOLKSWAGEN UNITED STATES, INC.
Hook spindles 10 - 222 A/11 in eyes - arrow - of subframe on left and right sides of vehicle.
Fig. 137: Setting Wooden Block Into Hanger Of Each Spindle 10 - 222 A/11 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Set a wooden block approx. 300 mm long into hanger of each spindle 10 - 222 A/11.
Hangers must face rearward.
Tighten winged nuts of spindles , ensuring that the wooden blocks lie against subframe - B -.
Remove engine/transmission jack V.A.G 1383 A from under subframe.
Place insert from a trolley jack into engine/transmission jack V.A.G 1383 A.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 101 © 2005 Mitchell Repair Information Company, LLC.
Fig. 138: Placing Engine/Transmission Jack V.A.G 1383 A Under Engine Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC.
Place engine/transmission jack V.A.G 1383 A under subframe and lightly press against it.
A - Wooden support
Fig. 139: Removing/Installing Coupling Rods On Left/Right From Stabilizer Bar Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove temporarily installed bolts - 3 - for subframe on left and right.
Install bolts - 2 - for air spring strut or suspension strut on lower control arm.
Fasten coupling rods on left and right - 1 - to stabilizer --> 40 - FRONT SUSPENSION .
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 102 © 2005 Mitchell Repair Information Company, LLC.
Fig. 140: Checking Inner Contour Of Sleeve In Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Before bolting on subframe, check inner contour of bonded rubber bushing sleeve in subframe - arrow -.
Bolt on subframe - arrows - --> 40 - FRONT SUSPENSION
Fig. 141: Placing Engine/Transmission Jack V.A.G 1383 A Under Engine Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC.
If an axle alignment was performed, the bolts must be replaced --> 40 - FRONT SUSPENSION
Tighten bolts to tightening torque --> 48 - STEERING .
Remove spindles 10 - 222 A/11 from subframe.
Inner contour of sleeve Rectangular Vehicle must be aligned after assembling the
subframe --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT
Round If steering wheel is crooked, a vehicle alignment must be performed --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT .
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 103 © 2005 Mitchell Repair Information Company, LLC.
Fig. 142: Identifying Universal Joint Bolt And Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC.
Install universal joint on steering gear and tighten bolt - B - to tightening torque --> 40 - FRONT SUSPENSION
If equipped, install shield - A - to steering gear --> 40 - FRONT SUSPENSION .
Fig. 143: Identifying Coolant Pipes, Nut & Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.
If equipped, install coolant pipes - 1 - on left longitudinal member. When doing this, fasten nut - arrow A- and bracket - arrow B - --> 82 AUXILIARY HEATER .
Connect front driveshaft --> Front driveshaft, removing and installing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 104 © 2005 Mitchell Repair Information Company, LLC.
Fig. 144: Removing/Installing Shield From Front Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Install shield - arrows - and tighten bolts to 10 Nm.
Install drive axles to flange shafts --> 40 - FRONT SUSPENSION .
Remove tensioner hooks VW 552.
Install left front and right wheel housing liners --> 66 - EXTERIOR EQUIPMENT .
Check gear oil in front final drive --> Gear oil in front final drive, checking.
If an underbody impact guard is located beneath the front final drive, install it --> 50 - BODY - FRONT .
Install front wheels --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT .
After installation, a vehicle alignment must be performed --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT .
Breather line for front final drive, routing
Fig. 145: Breather Line For Front Final Drive, Routing Courtesy of VOLKSWAGEN UNITED STATES, INC.
The breather line - 1 - runs from front final drive - 3 - , along behind right engine mount - 4 - and then is clipped to the air filter - 2 -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 105 © 2005 Mitchell Repair Information Company, LLC.
SEALS AT FRONT FINAL DRIVE, REPLACING
Left flange shaft oil seal, replacing
Fig. 146: Identifying Special Tools - Left Flange Shaft Oil Seal, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Punch VW 412
Thrust plate VW 432
Support channels VW 457
Slide hammer VW 771
Seal installer 2003/3
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 106 © 2005 Mitchell Repair Information Company, LLC.
Alignment fixture 3301
Sealing grease G 052 128 A1
Special tools, testers and auxiliary items required
Fig. 147: Identifying Kukko Tools Courtesy of VOLKSWAGEN UNITED STATES, INC.
- 3 - - Kukko 17/2 Separating device
Fig. 148: Thrust Plate T10260 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Thrust plate T10260
Removing
Remove front final drive --> Front final drive, removing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 107 © 2005 Mitchell Repair Information Company, LLC.
Fig. 149: Securing Slide Hammer VW 771 To Left Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure slide hammer VW 771 to left flange shaft.
Pull out left flange shaft.
Fig. 150: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 771/37.
Installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 108 © 2005 Mitchell Repair Information Company, LLC.
Fig. 151: Driving In New Oil Seal Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive in new oil seal up to stop.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary.
Fig. 152: Removing Old Circlip From Groove In Flange Shaft Using Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove old circlip - A - from groove in flange shaft using pliers.
B - Vise jaw protectors
Insert new circlip in groove of flange shaft, being careful not to over-stretch circlip.
Drive in flange shaft using a plastic head hammer.
Install front final drive --> Front final drive, installing.
Check gear oil in front final drive --> Gear oil in front final drive, checking.
Dust cap for flange shaft, replacing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 109 © 2005 Mitchell Repair Information Company, LLC.
Fig. 153: Pressing Off Dust Cap From Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press off dust cap - B - from flange shaft.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 154: Pressing Dust Cap Onto Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press dust cap - A - onto flange shaft.
Set sleeve 3301/3 in place with recess - arrow - facing dust cap - A -.
Right flange shaft seal, replacing
Special tools, testers and auxiliary items required
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 110 © 2005 Mitchell Repair Information Company, LLC.
Fig. 155: Slide Hammer-Multi-Purpose Tool Set VW 771 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Slide hammer VW 771
Pulling hook VW 771/37
Fig. 156: Thrust Plate T10259 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Thrust plate T10259
Sealing grease G 052 128 A1
Removing
Remove front final drive --> Front final drive, removing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 111 © 2005 Mitchell Repair Information Company, LLC.
Fig. 157: Securing Slide Hammer VW 771 To Right Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure slide hammer VW 771 to right flange shaft.
Pull out right drive flange.
Fig. 158: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 771/37.
Installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 112 © 2005 Mitchell Repair Information Company, LLC.
Fig. 159: Driving In New Oil Seal Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive in new oil seal up to stop.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary.
Fig. 160: Removing Old Circlip From Groove In Flange Shaft Using Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove old circlip - A - from groove in flange shaft using pliers.
B - Vise jaw protectors
Insert new circlip in groove of flange shaft, being careful not to over-stretch circlip.
Drive in flange shaft using a plastic head hammer.
Install front final drive --> Front final drive, installing.
Check gear oil in front final drive --> Gear oil in front final drive, checking.
Seal for driveshaft flange on front final drive, replacing (final drive removed)
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 113 © 2005 Mitchell Repair Information Company, LLC.
Fig. 161: Identifying Special Tools - Seal For Driveshaft Flange On Front Final Drive, Replacing (Final Drive Removed) (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Pressure plate VW 402
Punch VW 407
Punch VW 412
Slide hammer VW 771
Pulling hook 771/37
Sleeve 40 - 20
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:52 AM Page 114 © 2005 Mitchell Repair Information Company, LLC.
Fig. 162: Identifying Special Tools - Seal For Driveshaft Flange On Front Final Drive, Replacing (Final Drive Removed) (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Counter holder 3435
Torque wrench V.A.G 1576
Friction meter VAS 6222
Thrust plate T10183
- 3 - - Kukko 17/2 Separating device
Sealing grease G 052 128 A1
Loctite 648
2 Bolts M10 x 25
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 115 © 2005 Mitchell Repair Information Company, LLC.
Removing
Remove front final drive --> Front final drive, removing.
Lay front final drive on a workbench.
Fig. 163: Measure Friction Torque Using Friction Meter VAS 6222 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Before loosening drive pinion nut, measure friction torque.
Note friction torque value. After seal is replaced, friction torque must be restored to this value.
Use friction meter VAS 6222.
Fig. 164: Removing Hex Nut For Drive Shaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove hex nut for drive shaft flange.
A - 2 Bolts M10 x 25
When loosening the nut of the driveshaft flange, counterhold using counter holder 3435 (2nd technician required).
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 116 © 2005 Mitchell Repair Information Company, LLC.
Fig. 165: Marking Installation Position Of Driveshaft Flange Relative To Drive Pinion Courtesy of VOLKSWAGEN UNITED STATES, INC.
Mark installation position of driveshaft flange - arrow A - relative to drive pinion - arrow B -.
Pull off driveshaft flange. If difficult to remove, use slide hammer VW 771.
Fig. 166: Pulling Out Sealing Ring Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out sealing ring.
Clean threads for nut on drive pinion.
Installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 117 © 2005 Mitchell Repair Information Company, LLC.
Fig. 167: Driving New Seal In As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive new seal in as far as stop; be sure not to distort seal.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Before installing driveshaft flange, check dust cap for damage. Replace dust cap if necessary.
Install driveshaft flange, being aware of marking from removal .
Coat threads of new nut with locking fluid Loctite 648 .
Fig. 168: Removing Hex Nut For Drive Shaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Tighten new nut for drive pinion until friction torque measured prior to removal is attained .
A - 2 Bolts M10 x 25
When tightening the nut of the driveshaft flange, counterhold using counter holder 3435 (2nd technician required)
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 118 © 2005 Mitchell Repair Information Company, LLC.
Fig. 169: Measure Friction Torque Using Friction Meter VAS 6222 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Increase tightening torque gradually, frequently measuring friction torque. The friction torque measured prior to removal must not be exceeded! Otherwise front final drive must be replaced!
Install front final drive --> Front final drive, installing.
Check gear oil in front final drive --> Gear oil in front final drive, checking.
Dust cap for driveshaft flange, replacing
Fig. 170: Pressing Dust Cap Off Of Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press dust cap off of driveshaft flange.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 119 © 2005 Mitchell Repair Information Company, LLC.
Fig. 171: Pressing Dust Cap Onto Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press dust cap - A - onto driveshaft flange.
Installation position of dust cap: Depression on dust cap faces up toward sleeve 40 - 20.
NEEDLE BEARING FOR LEFT FLANGE SHAFT, REPLACING
Needle bearing for left flange shaft, replacing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 120 © 2005 Mitchell Repair Information Company, LLC.
Fig. 172: Identifying Special Tools - Needle Bearing For Left Flange Shaft, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Mandrel 30 - 505
Thrust pad 30 - 506 B
- 1 - - Kukko 21/6 Internal puller
- 4 - - Kukko 22/2 Counter-support
Needle bearing, removing
Remove front final drive --> Front final drive, removing.
Remove left flange shaft and seal --> Left flange shaft oil seal, replacing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 121 © 2005 Mitchell Repair Information Company, LLC.
Fig. 173: Pulling Out Needle Bearing For Left Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out needle bearing for left flange shaft.
A - Internal puller 37 to 46 mm, e.g. Kukko 21/6
B - Counter support, e.g. Kukko 22/2
Needle bearing, installing
Fig. 174: Driving In Needle Bearing For Left Flange Shaft Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive in needle bearing - A - for left flange shaft up to stop.
Install left flange shaft and seal --> Left flange shaft oil seal, replacing.
Install front final drive --> Front final drive, installing.
Check gear oil in front final drive --> Gear oil in front final drive, checking.
BONDED RUBBER BUSHING AT FRONT FINAL DRIVE, REPLACING
Bonded rubber bushing at front final drive, replacing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 122 © 2005 Mitchell Repair Information Company, LLC.
Fig. 175: Identifying Special Tools - Bonded Rubber Bushing At Front Final Drive, Replacing (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Thrust plate VW 442
Sleeve 30 - 14
Alignment fixture 3301
Alignment fixture 3346
Alignment fixture 3347
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 123 © 2005 Mitchell Repair Information Company, LLC.
Fig. 176: Identifying Special Tools - Bonded Rubber Bushing At Front Final Drive, Replacing (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Thrust pad VW 512
Thrust plate VW 554
Alignment fixture 3253
Alignment fixture T10030
Bonded rubber bushing, installation position
Bonded rubber bushings with 2 recesses
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 124 © 2005 Mitchell Repair Information Company, LLC.
Fig. 177: Bonded Rubber Bushings With 2 Recesses Courtesy of VOLKSWAGEN UNITED STATES, INC.
The recesses in the bushing must be vertical relative to final drive - arrows -.
Bonded rubber bushings with 4 recesses
Fig. 178: Bonded Rubber Bushings With 4 Recesses Courtesy of VOLKSWAGEN UNITED STATES, INC.
The smaller recesses - arrows - and smaller holes - A - of bushings must be vertical relative to final drive.
Bonded rubber bushing at driveshaft flange, pulling out and in
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 125 © 2005 Mitchell Repair Information Company, LLC.
Fig. 179: Pulling Out Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out bonded rubber bushing.
It is important to grease spindle 3346/2 with Molybdenum grease before using.
Pull in bonded rubber bushing - A -.
Fig. 180: Pulling In Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull in bonded rubber bushing - A - only so far until dimension - a - is achieved.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 126 © 2005 Mitchell Repair Information Company, LLC.
Fig. 181: Installation Depth For Bonded Rubber Bushing At Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Installation depth for bonded rubber bushing at driveshaft flange.
Dimension - a - = 47.5 mm
Bonded rubber bushing at front housing, pulling out and in
Fig. 182: Pulling Out Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out bonded rubber bushing.
It is important to grease spindle 3346/2 with Molybdenum grease before using.
To pull out, place special tool 3346/1 with flat shoulder facing toward bonded rubber bushing onto spindle 3346/2.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 127 © 2005 Mitchell Repair Information Company, LLC.
Fig. 183: Pulling In Bonded Rubber Bushing Until It Is Centered In Front Final Drive Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull in bonded rubber bushing - A - until it is centered in front final drive housing.
Bonded rubber bushing at extension tube for left flange shaft, pulling out and in
Removing and installing bonded rubber bushing on extension tube for left flange shaft is identical to the procedure for removing and installing bonded rubber bushing on rear final drive --> Bonded rubber bushing on rear final drive, replacing.
39R FINAL DRIVE, REAR DIFFERENTIAL
ELECTRICAL/ELECTRONIC COMPONENTS AND LOCATIONS FOR REAR FINAL DRIVE DIFFERENTIAL LOCK
Electrical/electronic components and locations for rear final drive differential lock
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 128 © 2005 Mitchell Repair Information Company, LLC.
Fig. 184: Electrical/Electronic Components And Locations For Rear Final Drive Differential Lock Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Differential lock control module J647
Location --> Location of Differential lock control module J647
Removing and installing --> Differential lock control module J647 , removing and installing
2 - Transfer case operating unit E473
Location --> Location of transfer case operating unit E473
Removing and installing --> 68 - INTERIOR EQUIPMENT .
3 - Differential lock motor V304
Location --> Location of Differential lock motor V304
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 129 © 2005 Mitchell Repair Information Company, LLC.
Removing and installing --> Differential lock motor V304 , removing and installing
The following components are integrated into differential lock motor V304 :
Motor temperature sensor G407
Differential lock position sensor 1 G460
Differential lock position sensor 2 G461
Brake for locking motor
4 - Data Link Connector (DLC)
Location --> Data Link Connector (DLC)
5 - Multi-function display in instrument cluster
Indicates condition and information about differential lock in rear final drive
Location of Differential lock control module J647
Fig. 185: Location Of Differential Lock Control Module J647 Courtesy of VOLKSWAGEN UNITED STATES, INC.
The differential lock control module J647 is located behind the side trim on the left rear wheel housing - arrow -.
Differential lock control module J647 , removing and installing --> Differential lock control module J647 , removing and installing.
Location of transfer case operating unit E473
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 130 © 2005 Mitchell Repair Information Company, LLC.
Fig. 186: Location Of Transfer Case Operating Unit E473 Courtesy of VOLKSWAGEN UNITED STATES, INC.
The transfer case operating unit E473 - 1 - is located in the shift cover - 2 - of the center console.
Transfer case operating unit E473 , removing and installing --> 70 - INTERIOR TRIM .
Location of Differential lock motor V304
Fig. 187: Setting Differential Lock Motor V304 With Holder For Connector Into Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
The differential lock motor V304 - A - is located in front of the left flange shaft on the rear final drive.
Differential lock motor V304 , removing and installing --> Differential lock motor V304 , removing and installing
Data Link Connector (DLC)
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 131 © 2005 Mitchell Repair Information Company, LLC.
Fig. 188: Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.
The Data Link Connector (DLC) is located in the cover of the drivers side footwell.
Differential lock control module J647 , removing and installing
Removing
Check whether a coded radio is installed. If so, obtain radio anti-theft coding.
Switch ignition and all electrical consumers off, and remove ignition key.
Disconnect Ground (GND) terminal connector from battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
Remove left rear side trim --> 72 - SEAT - FRAMES .
Vehicles with Four-zone Climatronic
Move rear auxiliary heater and air conditioner unit into service position --> 87 AIR CONDITIONING .
Continued for all vehicles
Fig. 189: Identifying Differential Lock Control Module J647 Connector, Bolt & Differential Lock Control Module J647
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 132 © 2005 Mitchell Repair Information Company, LLC.
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Separate connector - 1 - at differential lock control module J647.
Remove bolt - 2 -.
Unclip holder with differential lock control module J647 - 3 - from structure - arrows - and remove holder with differential lock control module J647.
Installing
Installation is in reverse order of removal. Note the following:
Fig. 190: Identifying Differential Lock Control Module J647 Connector, Bolt & Differential Lock Control Module J647 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Clip holder with differential lock control module J647 - 3 - into structure - arrows -.
Tighten bolt - 2 - to 2 Nm.
Connect Ground (GND) terminal connector to battery and perform work sequences after connecting battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
GEAR OIL IN REAR FINAL DRIVE, CHECKING
Gear oil in rear final drive, checking
Transmission oil specification --> Code letters, transmission allocation, gear ratios, capacities
Special tools, testers and auxiliary items required
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 133 © 2005 Mitchell Repair Information Company, LLC.
Fig. 191: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Torque wrench V.A.G 1331
Fig. 192: Removing Sealing Plug For Gear Oil Inspection Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove sealing plug for gear oil inspection - arrow -.
The oil level is correct when the rear final drive is filled to the lower edge of the filler hole.
Fasten bolt - arrow - with new seal.
When initially filling rear final drive
Remove bolt - arrow -.
Top off oil to lower edge of filler hole.
Fasten bolt - arrow - with new seal.
Tightening torque Oil filler plug to rear final drive 35 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 134 © 2005 Mitchell Repair Information Company, LLC.
REAR FINAL DRIVE, REMOVING AND INSTALLING
Rear final drive, removing and installing
Fig. 193: Identifying Special Tools - Rear Final Drive, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A with universal transmission adapter 1359/2
Rear final drive, removing
Raise vehicle.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 135 © 2005 Mitchell Repair Information Company, LLC.
If an underbody impact guard is located beneath the rear final drive, remove it --> 50 - BODY - FRONT .
Remove rear part of exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Fig. 194: Identifying Mark On Driveshaft Flange & Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Check whether there is a marking (colored marking) on rear driveshaft and on driveshaft flange at rear final drive.
If no markings can be found, mark in color the position of the driveshaft flange - arrow A - to rear final drive - arrow B -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 136 © 2005 Mitchell Repair Information Company, LLC.
Fig. 195: Disconnecting Rear Driveshaft From Rear Final Drive And Tie Up Courtesy of VOLKSWAGEN UNITED STATES, INC.
Disconnect rear driveshaft from rear final drive and tie up - arrow - --> Rear driveshaft, removing and installing.
If equipped, remove differential lock motor V304 --> Differential lock motor V304 , removing.
Fig. 196: Disconnecting Left/Right Drive Shafts And Tie-Up Courtesy of VOLKSWAGEN UNITED STATES, INC.
Disconnect left - 2 - and right - 1 - drive shafts and tie-up.
Place engine/transmission jack V.A.G 1383 A with universal transmission adapter V.A.G 1359/2 under rear final drive.
Remove bolts and nuts for rear final drive at subframe - arrows -.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 137 © 2005 Mitchell Repair Information Company, LLC.
Fig. 197: Tipping Up Rear Final Drive At Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Tip up rear final drive at driveshaft flange - A -.
Lower rear final drive slightly and pull breather line off connection nipple.
Lower rear final drive.
Rear final drive, installing
Installation is in reverse order of removal. Note the following:
Always replace bolts for rear driveshaft.
Fig. 198: Identifying Mark On Driveshaft Flange & Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
To prevent imbalance, the rear driveshaft flange - arrow A - and rear final drive - arrow B - must be installed so that the colored markings from the factory or those subsequently made are in alignment.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 138 © 2005 Mitchell Repair Information Company, LLC.
Fig. 199: Fastening Rear Final Drive To Subframe Courtesy of VOLKSWAGEN UNITED STATES, INC.
Fasten rear final drive to subframe - arrows - --> 42 - REAR SUSPENSION .
Fasten right - 1 - and left - 2 - driveshafts at flange shafts --> 42 - REAR SUSPENSION .
If equipped, install the differential lock motor V304 --> Differential lock motor V304 , installing.
Connect rear driveshaft --> Rear driveshaft, removing and installing.
Install center bearing for driveshaft, so that it is free of stress --> Rear driveshaft center bearing, installing stress-free.
Check gear oil in rear final drive --> Gear oil in rear final drive, checking.
If an underbody impact guard is located beneath the rear final drive, install it --> 50 - BODY - FRONT .
Install rear part of exhaust system -->
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Breather line for rear final drive, routing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 139 © 2005 Mitchell Repair Information Company, LLC.
Fig. 200: Breather Line For Rear Final Drive, Routing Courtesy of VOLKSWAGEN UNITED STATES, INC.
The breather line - A - runs from the rear final drive - B - over the subframe to connection - C -.
The breather line - A - is clipped into this.
DIFFERENTIAL LOCK MOTOR V304 , REMOVING AND INSTALLING
Differential lock motor V304 , removing and installing
Special tools, testers and auxiliary items required
Fig. 201: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Torque wrench V.A.G 1331
Differential lock motor V304 , removing
Separate two connectors at differential lock motor.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 140 © 2005 Mitchell Repair Information Company, LLC.
Fig. 202: Setting Differential Lock Motor V304 With Holder For Connector Into Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove four bolts and remove differential lock motor differential lock motor - A - with holder for connector - B -.
Differential lock motor V304 , installing
Fig. 203: Replacing O-Ring On Differential Lock Motor V304 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Replace O-ring - arrow - on Differential lock motor V304
NOTE: Differential lock motor V304 is delivered as a replacement part with O-ring
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 141 © 2005 Mitchell Repair Information Company, LLC.
Fig. 204: Setting Differential Lock Motor V304 With Holder For Connector Into Rear Final Drive Courtesy of VOLKSWAGEN UNITED STATES, INC.
Set Differential lock motor V304 - A - with holder for connector - B - into rear final drive, and install and tighten four bolts.
Connect two connectors at Differential lock motor V304.
Checking gear oil in rear final drive --> Gear oil in rear final drive, checking.
SEALS AT REAR FINAL DRIVE, REPLACING
Seal for left flange shaft, replacing (vehicles without differential lock)
installed.
O-ring is secured with a protective sleeve.
Remove protective sleeve before installing Differential lock motor V304.
Tightening torque Differential lock motor V304 at rear final drive 8 Nm
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 142 © 2005 Mitchell Repair Information Company, LLC.
Fig. 205: Identifying Special Tools - Seal For Left Flange Shaft, Replacing (Vehicles Without Differential Lock) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Pressure plate VW 402
Punch VW 412
Slide hammer VW 771
Pulling hook VW 771/37
Tube 3146
- 3 - - Kukko 17/2 Separating device
Sealing grease G 052 128 A1
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 143 © 2005 Mitchell Repair Information Company, LLC.
Special tools, testers and auxiliary items required
Fig. 206: Thrust Plate T10256 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Thrust plate T10256
Removing
Remove rear final drive --> Rear final drive, removing.
Fig. 207: Securing Slide Hammer VW 771 To Left Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure slide hammer VW 771 to left flange shaft.
Pull out left flange shaft.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 144 © 2005 Mitchell Repair Information Company, LLC.
Fig. 208: Pulling Out Seal For Flange Shaft Using VW 771/1 And VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out seal for flange shaft using VW 771/1 and VW 771/37.
Installing
Fig. 209: Driving In New Oil Seal Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive in new oil seal up to stop.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Before installing the flange shaft, check the dust cap for damage. Replace dust cap if necessary.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 145 © 2005 Mitchell Repair Information Company, LLC.
Fig. 210: Removing Old Circlip From Groove In Flange Shaft Using Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove old circlip - A - from groove in flange shaft using pliers.
B - Vise jaw protectors
Insert new circlip in groove of flange shaft, being careful not to over-stretch circlip.
Drive in flange shaft using a plastic head hammer.
Install rear final drive --> Rear final drive, installing.
Checking gear oil in rear final drive --> Gear oil in rear final drive, checking.
Dust cap for flange shaft, replacing
Fig. 211: Pressing Off Dust Cap From Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press off dust cap - B - from flange shaft.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 146 © 2005 Mitchell Repair Information Company, LLC.
Fig. 212: Pressing Dust Cap Onto Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press dust cap - A - onto flange shaft.
Seal for left flange shaft, replacing (vehicles with differential lock)
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 147 © 2005 Mitchell Repair Information Company, LLC.
Fig. 213: Identifying Special Tools - Seal For Left Flange Shaft, Replacing (Vehicles With Differential Lock) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Pressure plate VW 401
Pressure plate VW 402
Punch VW 407
Punch VW 412
Slide hammer VW 771
Pulling hook VW 771/37
Sleeve 3144
Sealing grease G 052 128 A1
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 148 © 2005 Mitchell Repair Information Company, LLC.
Special tools, testers and auxiliary items required
Fig. 214: Identifying Kukko Tools Courtesy of VOLKSWAGEN UNITED STATES, INC.
- 3 - - Kukko 17/2 Separating device
Fig. 215: Thrust Plate T10258 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Thrust plate T10258
Removing
Remove rear final drive --> Rear final drive, removing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 149 © 2005 Mitchell Repair Information Company, LLC.
Fig. 216: Securing Slide Hammer VW 771 To Left Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure slide hammer VW 771 to left flange shaft.
Pull out left flange shaft.
Fig. 217: Pulling Out Seal For Flange Shaft Using VW 771/1 And VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37.
Installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 150 © 2005 Mitchell Repair Information Company, LLC.
Fig. 218: Driving In New Oil Seal Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive in new oil seal up to stop.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary.
Fig. 219: Removing Old Circlip From Groove In Flange Shaft Using Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove old circlip - A - from groove in flange shaft using pliers.
B - Vise jaw protectors
Insert new circlip in groove of flange shaft, being careful not to over-stretch circlip.
Drive in flange shaft using a plastic head hammer.
Install rear final drive --> Rear final drive, installing.
Checking gear oil in rear final drive --> Gear oil in rear final drive, checking.
Dust cap for flange shaft, replacing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 151 © 2005 Mitchell Repair Information Company, LLC.
Fig. 220: Pressing Off Dust Cap From Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press off dust cap - B - from flange shaft.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 221: Pressing Dust Cap Onto Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press dust cap - A - onto flange shaft.
Seal for right flange shaft, replacing (vehicles without differential lock)
Special tools, testers and auxiliary items required
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 152 © 2005 Mitchell Repair Information Company, LLC.
Fig. 222: Slide Hammer-Multi-Purpose Tool Set VW 771 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Slide hammer VW 771
Pulling hook VW 771/37
Fig. 223: Thrust Plate T10181 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Thrust plate T10181
Sealing grease G 052 128 A1
Removing
Remove rear final drive --> Rear final drive, removing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 153 © 2005 Mitchell Repair Information Company, LLC.
Fig. 224: Securing Slide Hammer VW 771 To Right Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure slide hammer VW 771 to right flange shaft.
Pull out right drive flange.
Fig. 225: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37.
Installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 154 © 2005 Mitchell Repair Information Company, LLC.
Fig. 226: Driving In New Oil Seal Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive in new oil seal up to stop.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary.
Fig. 227: Removing Old Circlip From Groove In Flange Shaft Using Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove old circlip - A - from groove in flange shaft using pliers.
B - Vise jaw protectors
Insert new circlip in groove of flange shaft, being careful not to over-stretch circlip.
Drive in flange shaft using a plastic head hammer.
Install rear final drive --> Rear final drive, installing.
Check gear oil in rear final drive --> Gear oil in rear final drive, checking.
Seal for right flange shaft, replacing (vehicles with differential lock)
Special tools, testers and auxiliary items required
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 155 © 2005 Mitchell Repair Information Company, LLC.
Fig. 228: Slide Hammer-Multi-Purpose Tool Set VW 771 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Slide hammer VW 771
Pulling hook VW 771/37
Fig. 229: Thrust Plate T10257 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Thrust plate T10257
Sealing grease G 052 128 A1
Removing
Remove rear final drive --> Rear final drive, removing.
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 156 © 2005 Mitchell Repair Information Company, LLC.
Fig. 230: Securing Slide Hammer VW 771 To Right Flange Shaft Courtesy of VOLKSWAGEN UNITED STATES, INC.
Secure slide hammer VW 771 to right flange shaft.
Pull out right drive flange.
Fig. 231: Pulling Out Sealing Ring For Flange Shaft Using Slide Hammer-Complete Set VW 771 And Additional Part For VW 771 VW 771/37 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out sealing ring for flange shaft using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37.
Installing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 157 © 2005 Mitchell Repair Information Company, LLC.
Fig. 232: Driving In New Oil Seal Up To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive in new oil seal up to stop.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Before installing flange shaft, check dust cap for damage. Replace dust cap if necessary.
Fig. 233: Removing Old Circlip From Groove In Flange Shaft Using Pliers Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove old circlip - A - from groove in flange shaft using pliers.
B - Vise jaw protectors
Insert new circlip in groove of flange shaft, being careful not to over-stretch circlip.
Drive in flange shaft using a plastic head hammer.
Install rear final drive --> Rear final drive, installing.
Check gear oil in rear final drive --> Gear oil in rear final drive, checking.
Sealing ring for driveshaft flange on rear final drive, replacing (final drive removed)
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 158 © 2005 Mitchell Repair Information Company, LLC.
Fig. 234: Identifying Special Tools - Sealing Ring For Driveshaft Flange On Rear Final Drive, Replacing (Final Drive Removed) (1 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Pressure plate VW 402
Punch VW 407
Punch VW 412
Slide hammer VW 771
Pulling hook VW 771/37
Sleeve 40 - 20
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 159 © 2005 Mitchell Repair Information Company, LLC.
Fig. 235: Identifying Special Tools - Sealing Ring For Driveshaft Flange On Rear Final Drive, Replacing (Final Drive Removed) (2 Of 2) Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Handle-Hold Dr. Shaft Flange 3145 (change: expand holes to 10 mm diameter)
Torque wrench V.A.G 1576
Friction meter VAS 6222
Thrust plate T10182
- 3 - - Kukko 17/2 Separating device
Sealing grease G 052 128 A1
Loctite 648
2 Bolts M10 x 25
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 160 © 2005 Mitchell Repair Information Company, LLC.
Removing
If necessary, expand holes in Counterhold 3145 to 10 mm diameter.
Remove rear final drive --> Rear final drive, removing.
Set rear final drive on a workbench.
Fig. 236: Measuring Friction Torque Courtesy of VOLKSWAGEN UNITED STATES, INC.
Before loosening drive pinion nut, measure friction torque.
Note friction torque value. After seal is replaced, friction torque must be restored to this value.
Use friction meter VAS 6222.
Fig. 237: Removing/Installing Flange/Drive Shaft Hex Nut Courtesy of VOLKSWAGEN UNITED STATES, INC.
Remove flange/drive shaft hex nut as follows:
Secure Handle-Hold Dr. Shaft Flange 3145 with 2 bolts M10 x 25 to driveshaft flange - arrows -.
When loosening the driveshaft flange nut, counterhold using Handle-Hold Dr. Shaft Flange 3145 (2nd technician required).
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 161 © 2005 Mitchell Repair Information Company, LLC.
Fig. 238: Marking Installation Position Of Driveshaft Flange Relative To Drive Pinion Courtesy of VOLKSWAGEN UNITED STATES, INC.
Mark installation position of driveshaft flange - arrow A - relative to drive pinion - arrow B -.
Pull off flange for driveshaft. If the task is difficult, use slide hammer VW 771.
Pull out sealing ring using slide hammer-complete set VW 771 and additional part for VW 771 VW 771/37.
Clean threads for nut on drive pinion.
Installing
Fig. 239: Driving New Seal In As Far As Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Drive new seal in as far as the stop; be sure not to distort seal.
Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1 .
Before installing driveshaft flange, check dust cap for damage. Replace dust cap if necessary.
Install driveshaft flange, being aware of marking from removal .
Coat threads of new nut with locking fluid Loctite 648 .
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 162 © 2005 Mitchell Repair Information Company, LLC.
Fig. 240: Removing/Installing Flange/Drive Shaft Hex Nut Courtesy of VOLKSWAGEN UNITED STATES, INC.
Tighten new nut for drive pinion until friction torque measured prior to removal is attained.
When tightening the nut of the driveshaft flange, counterhold using Handle-Hold Dr. Shaft Flange 3145 (2nd technician required).
Fig. 241: Measuring Friction Torque Courtesy of VOLKSWAGEN UNITED STATES, INC.
Increase tightening torque gradually, frequently measuring friction torque. The friction torque measured prior to removal must not be exceeded! Otherwise the rear final drive must be replaced!
Install rear final drive --> Rear final drive, installing.
Checking gear oil in rear final drive --> Gear oil in rear final drive, checking.
Dust cap for driveshaft flange, replacing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 163 © 2005 Mitchell Repair Information Company, LLC.
Fig. 242: Pressing Dust Cap Off Of Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press dust cap off of driveshaft flange.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 243: Pressing Dust Cap Onto Driveshaft Flange Courtesy of VOLKSWAGEN UNITED STATES, INC.
Press dust cap - A - onto driveshaft flange.
Installation position of dust cap: Depression on dust cap faces up toward sleeve 40 - 20.
BONDED RUBBER BUSHING ON REAR FINAL DRIVE, REPLACING
Bonded rubber bushing on rear final drive, replacing
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 164 © 2005 Mitchell Repair Information Company, LLC.
Fig. 244: Identifying Special Tools - Bonded Rubber Bushing On Rear Final Drive, Replacing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
Thrust plate VW 442
Thrust plate VW 554
Sleeve 30 - 14
Alignment fixture 3301
Alignment fixture 3346
Alignment fixture 3347
Bonded rubber bushing, installation position
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 165 © 2005 Mitchell Repair Information Company, LLC.
Bonded rubber bushings with 2 recesses
Fig. 245: Bonded Rubber Bushing, Installation Position Courtesy of VOLKSWAGEN UNITED STATES, INC.
The recesses in the bushing must be vertical relative to final drive - arrows -.
Bonded rubber bushings with 4 recesses
Fig. 246: Bonded Rubber Bushings With 4 Recesses Courtesy of VOLKSWAGEN UNITED STATES, INC.
The smaller recesses - arrows - and smaller holes - A - of bushings must be vertical relative to final drive.
Bonded rubber bushing at driveshaft flange, pulling out and in
Always grease spindle 3346/2 with Molybdenum grease before inserting
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 166 © 2005 Mitchell Repair Information Company, LLC.
Fig. 247: Pulling Out Bonded Rubber Bushing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Pull out bonded rubber bushing.
It is important to grease spindle 3346/2 with Molybdenum grease before using.
Pull in bonded rubber bushing - A - to stop.
Fig. 248: Pulling In Bonded Rubber Bushing To Stop Courtesy of VOLKSWAGEN UNITED STATES, INC.
Rear bonded rubber bushing, pulling out and in
The process for pulling out and in the rear bonded rubber bushing at the rear final drive is identical to the process for the bonded rubber bushing at the driveshaft flange --> Bonded rubber bushing at driveshaft flange, pulling out and in.
Before pulling out a bonded rubber bushing, the corresponding flange shaft must first be removed --> Seal for left flange shaft, replacing (vehicles without differential lock).
2006 Volkswagen Touareg
REAR DIFFERENTIAL Rear Final Drive
Microsoft
Sunday, September 20, 2009 9:03:53 AM Page 167 © 2005 Mitchell Repair Information Company, LLC.