Transfer Box and Final Drive PDF

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Amarok 2011 ➤
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00 - Technical data
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34 - Controls, housing
39 - Final drive - rear differential
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39 - Final drive - front differential
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39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg D3E8028924F

Amarok 2011 ➤
Transfer box and final drive - Edition 09.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Overview - four-wheel drive power train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Transfer box identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Location on transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Identification code, assembly allocation, capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Identifying front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3.1 Location on front final drive . . . . . . . . s.w.ag. e.n.A.G.. V. o.l . .w.ag. e.n.A.G.d.oe. s. . . . . . . . . . . . . . . . . . . . . 3
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3.2 Identification code, assembly allocation, d by
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capacities . . . . . . . . . . .ot. g.ua. . . . . . . . . . . . . . . . . 3
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4 Rear final drive . . . . . . . . . t.ho.ri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .tee. o. . . . . . . . . . . . . 4
4.1 Identification code, assembly au allocation, ratios, capacities . . . . . . . . . . . . r.ac. . . . . . . . . . . 4
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5 Four-wheel drive - notes on performance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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6 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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6.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1 Connecting vehicle diagnosis, testing and information system VAS 5051B or vehicle
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diagnosis and service information system VAS 5052 A and selecting functions . . . . . . . . 8
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2 Electrical and electronic components and their locations for four-wheel drive . . . . . . . . . . 10
2.1 Removing and installing transfer box control unit J646 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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3 Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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4 Checking oil level in transfer box or adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 Assembly overview - transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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6 Renewing oil seals on transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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6.1 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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6.2 Renewing output shaft oil seal for front propshaft (transfer box installed) . . . . . . . . . . . . . . 18
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6.3 Renewing propshaft flange oil seal (transfer box installed) . . . . . . . . . . . . . . . . . . . . . . . . 20
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7 Removing and installing Hall sender for transfer box G759 . . . . . . . . . . . . . . . . . . . . . . . . um
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8 Removing and installing transfer box control motor V455 . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1 Rear final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2 Function of rear axle differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3 Electrical and electronic components and their locations for rear axle differential lock . . . . 29
4 Renewing the seal for the propshaft flange of the rear axle . . . . . . . . . . . . . . . . . . . . . . . . 30
5 Checking oil level in rear final drive or adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1 Front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Removing and installing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Renewing oil seals on front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4 Renewing dust cap for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5 Renewing dust cap for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4 Renewing needle bearing for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5 Renewing bonded rubber bush on front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Contents i
Amarok 2011 ➤
5.1 Pulling bonded rubber bush on rear housing out and in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.2 Pulling bonded rubber bush out of and into front of housing . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3 Pulling bonded rubber bush on left of housing out and in . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6 Checking oil level in front final drive or adding oil . . . . . a.g.en. A. G. ..V.ol.ks. w. a.g.en. A. G. .do. . . . . . . . . . . 56
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1 Propshafts . . . . . . . . . . . . . . . . . . . . . . . .au.th. . . . . . . . . . .
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1.1 Assembly overview - propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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1.2 Removing and installing front propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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1.3 Removing and installing rear propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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ii Contents
Amarok 2011 ➤
00 – Technical data
1 Overview - four-wheel drive power train
1 - Front final drive

❑ Removing and installing
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⇒ page 10
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⇒ page 12
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5 - Rear propshaft
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⇒ page 61
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6 - Rear final drive

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1. Overview - four-wheel drive power train 1

Amarok 2011 ➤
2 Transfer box identification

Transfer box 07C is allocated to manual gearbox 06C.
A reduction gearing is integrated into the transfer box.
Codes ⇒ page 2 .
2.1 Location on transfer

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Production date -arrow A- and identification code -arrow B- of
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Additional data depend on manufacture.

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Transfer box 0C7

Identification code LEP
Allocation Model Amarok 2011 ►
Engine 2.0 l - 120 kW
Capacity 1.25 l
The following data can be found in the ⇒ Electronic parts cata‐
logue „ETKA“ .
♦ Allocation to corresponding vehicle by identification code of
manual gearbox
♦ Specification of gear oil
2 Rep. gr.00 - Technical data

Amarok 2011 ➤
3 Identifying front final drive

Front final drive 0C1 is allocated to manual gearbox 06C.
Codes ⇒ page 3 .
3.1 Location on front final drive

Location on front final drive -arrow-
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Codes -arrow- and manufacturing data for front final drive
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Identifica‐ Day Month Year (2010)

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Identification code MQL
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Allocation Model Amarok 2011 ►
Engine 2.0 l - 120 kW
Capacity 0.8 l
The following data can be found in the ⇒ Electronic parts cata‐
logue „ETKA“ .
♦ Allocation to corresponding vehicle by engine code
3. Identifying front final drive 3

Amarok 2011 ➤
4 Rear final drive
4.1 Identification code, assembly allocation, ratios, capacities

Rear final drive 0CC
Identification code MQA MQB
Allocation Model Amarok 2011 ► Amarok 2011 ►
Engine 2.0 l - 120 kW 2.0 l - 120 kW
Ratio Final drive i = 4.1 i = 4.1
Capacity 1.5 l1) 1.5 l1)
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Amarok 2011 ➤
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5 Four-wheel drive - notes on perform‐ or eo
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5. Four-wheel drive - notes on performance test 5

Amarok 2011 ➤
6 General repair notes

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
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♦ When installing the transfer box, ensure that the dowel sleeves
hole
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between the gearbox and transfer box are correctly installed.
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♦ Always renew retaining rings for front propshaft on transfer
box and front final drive.
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♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
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♦ Allocate bolts and other components using ⇒ Electronic parts
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♦ When changing transfer box, top gearbox up with gear oil
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♦ Capacity of transfer box ⇒ page 2 .

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♦ When changing front final drive, top up with gear oil

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When changing rear axle, top up with gear oil ⇒ page 35 .

Capacity of rear final drive ⇒ page 4 .
6.1.3 Seals and sealing rings

♦ Renew seals.
♦ Radial oil seals.
Before installing:
Lightly oil outer diameter and half-fill space between sealing lips
-arrow- with grease -G 052 128 A1- .
After installation:
♦ Check oil level in transfer box ⇒ page 14 .
♦ Checking oil level in front final drive ⇒ page 56 .
♦ Checking oil level in rear final drive ⇒ page 3 .
6.1.4 Locking devices

♦ Renew retaining rings.
♦ Do not overstretch retaining rings.
♦ Retaining rings must locate properly in grooves.

Amarok 2011 ➤
6.1.5 Nuts and bolts

♦ Loosen and tighten bolts and nuts for covers and housings
diagonally.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Always renew self-locking bolts and nuts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
6.1.6 Bearing
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
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6. General repair notes 7

Amarok 2011 ➤
34 – Controls, housing
1 Connecting vehicle diagnosis, testing
and information system -VAS 5051B-
or vehicle diagnosis and service in‐
formation system -VAS 5052 A- and
selecting functions
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -VAS
5051B- or successor.
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WARNING
To avoid accident risks, proceed as follows during measuring

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♦ Use only vehicle diagnosis, testing and information sys‐

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8 Rep. gr.34 - Controls, housing

Amarok 2011 ➤
– With ignition switched off, connect vehicle diagnosis, testing

and information system -VAS 5051B- to diagnostic connec‐
tion.
Location: Driver footwell.
– Switch on tester.
The tester is operational when it displays a picture of a car.
– Switch on ignition.
Starting „guided fault finding“
– Touch Guided fault finding button on screen.
– Select in succession:
♦ Brand
♦ Model
♦ Model year
♦ Version
♦ Engine code
– Confirm input data.
Note
Wait until tester has read all control units in vehicle.
– Press Goto button and select Select function/compo-

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orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Connecting vehicle diagnosis, testing and information system VAS 5051B or vehicle diagnosis and service information system VAS
5052 A and selecting functions 9

Amarok 2011 ➤
2 Electrical and electronic components

and their locations for four-wheel
drive
Note
♦ Electrical and electronic components of rear axle differential

lock ⇒ page 29
♦ Refer to ⇒ Self-study programme No. 464 ; Power transmis‐
sion for more information about function.
♦ Refer to ⇒ Amarok owner's manual for more information and
notes on safety.
1 - Transfer box control unit -

J646-
❑ Location: under dash
panel
⇒ page 11
2 - Diagnostic connection
❑ Location: in driver foot‐
well
3 - Running gear programme
switch -E631- agen
AG. Volkswagen AG d
oes
lksw not
❑ Deactivate for four- by
Vo gu
ara
wheel drive rised
nte
ho eo
❑ Remove by removing aut ra
s c
selector mechanism s
ce
e
cover ⇒ General body

nl
pt
du
an
repairs, interior; Rep.
itte
y li
gr. 68 ; Compartments,
erm
ab
ility
covers and trims; Re‐
ot p
moving and installing
wit
, is n
h re
centre console
hole
spec
4 - Transfer box operating unit
es, in part or in w
❑ With reduction gearing t to the co

warning lamp in transfer
box operating unit -
rrectness of i
K182-
❑ With inter-axle lock-up
l purpos
warning lamp in transfer

box operating unit -
nform
ercia
K183-
m
❑ With rear axle differen‐

at
om
tial lock warning lamp in

on
c
in t
transfer box operating

or
his
e
unit -K184-
at
do
priv
❑ Remove by removing
um
for
selector mechanism
en
ng
t.
yi
cover ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments, covers and trims; Removing and
Co
Cop py
installing centre console
t. rig
gh ht
pyri by
Vo
o
5 - Running gear programme switch -E631- by c lksw
cted agen
Prote AG.
❑ Activate for four-wheel drive
❑ Remove by removing selector mechanism cover ⇒ General body repairs, interior; Rep. gr. 68 ; Com‐
partments, covers and trims; Removing and installing centre console

Amarok 2011 ➤
6 - Transfer box control motor -V455-

❑ Location: on transfer box
❑ Removing and installing ⇒ page 25
7 - Transfer box inter-axle lock-up switch -F438-
8 - Hall sender for transfer box -G759-
2.1 Removing and installing transfer box

control unit -J646-
Removing
– Remove connectors -1- and -3- on transfer box control unit -
J646- -2-.
– Push locks on bracket in direction of arrow and remove trans‐
fer box control unit -J646- .
Installing
Install in reverse order of removal. During this step, observe the
following:
Transfer box control unit -J646- must engage in bracket.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Electrical and electronic components and their locations for four-wheel drive 11
Amarok 2011 ➤
3 Removing and installing transfer box

♦ Torque wrench -V.A.G 1331-
♦ Engine and gearbox jack -V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
♦ Grease for drive shafts -G 052 738 A2-
t to the co
Removing
rrectness of i
– Remove rear propshaft ⇒ page 61 .
– Remove front propshaft ⇒ page 59 .
l purpos
– Pull off connector -arrows- and unclip wiring harness from nform
ercia
transfer box.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
. Volkswagen AG
a gen AG d
– Pull breather
Vol line -arrow- off transfer box.ot g
ksw
oes
n
by ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Position engine and gearbox jack -V.A.G 1383 A- under trans‐
rrectness of i
fer box.
l purpos
– Unscrew and remove transfer box/gearbox connecting bolts.

– Press transfer box off gearbox.
nform
ercia
– Lower transfer box with engine and gearbox jack -V.A.G 1383
m
a
A- .
com
tion in
Installing
r
te o
thi
s
iva

do
r
rp
following:
um
fo
en
ng
t.
yi
– Check whether dowel sleeves for aligning gearbox and trans‐
Co
op py
fer box are fitted in gearbox; install if necessary.
t. C rig
gh ht
pyri by
Vo
co lksw
by
– Always renew oil seal to seal transfer box and gearbox -1- and
cted agen
Prote AG.
lubricate lightly.
– Grease transfer box input shaft splines and gearbox output
shaft splines with drive shaft grease -G 052 738 A2- .
– Push transfer box completely onto gearbox, ensuring that
transfer box input shaft splines are centred as they are guided
onto the gearbox output shaft.
Caution
Do not use securing bolts to pull transfer box onto the gearbox.
Otherwise transfer box will cant.
If splines are correctly positioned and shafts are centred, then

transfer box will slide to stop against gearbox.
– Install front propshaft ⇒ page 59 .
– Install rear propshaft ⇒ page 61 .
– Check oil level in transfer box ⇒ page 14 .
Torque setting
Transfer box to gearbox 45 Nm
3. Removing and installing transfer box 13

Amarok 2011 ➤
4 Checking oil level in transfer box or

adding oil lksw
agen
AG. Volkswagen AG d
oes
not
Vo gu
y
Gearbox oil specification ⇒ Electronic parts catalogue „ETKA“
rise
d b ara
nte
tho eo
Special tools and workshop equipment required s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Note
m
a
com
tion in
♦ Oil level is below oil filler hole.
r
te o
thi
s
iva
♦ Make a tool to check oil level.
do
r
rp
cum
fo
en
ng
t.
Dimension -a- = 37 mm
yi Co
Cop py
t. rig
Dimension -b- = 60 mm gh ht
pyri by
Vo
co lksw
by
Perform the following steps: Prote
cted AG.
agen
– Raise vehicle ⇒ Maintenance ; Booklet 11 .
– Remove oil filler plug -1-.

– Insert locally manufactured tool into filler hole downwards as
far as possible.
– Pull out tool and check oil level on tool. Top up oil if necessary.
Gear oil level is correct if oil level is 32...37 mm below lower edge
of filler hole.
– Screw in new oil filler plug and tighten to 27 Nm.
When filling with oil, note the following:
– Remove oil filler plug -1-.
– Fill 1.25 l of gear oil.
– Screw in new oil filler plug and tighten to 27 Nm.

Amarok 2011 ➤
5 Assembly overview - transfer box
1 - Transfer box
2 - Breather pipe
❑ Removing ⇒ page 16
❑ Driving in ⇒ page 16
3 - Seal
❑ For input shaft
4 - Seal
❑ Always renew
❑ Insert in groove in input
shaft ⇒ page 16
5 - Dowel sleeve
❑ Qty. 2
❑ For centring gearbox/
transfer box
6 - Transfer box inter-axle lock-
up switch -F438- , 27 Nm
7 - Seal
❑ Renew if damaged
8 - Retaining ring
❑ On input shaft for front
propshaft
❑ Renew
AG. Volkswagen AG d
9 - Seal agen oes
olksw not
y V gu
❑ On output shaft for front d b ara
ise nte
propshaft thor eo
au ra
❑ Renew if damaged ss c
ce
le
un
10 - Seal
pt
an
d
itte
y li
❑ For output shaft for front

rm
ab
propshaft
pe
ility
ot
wit
❑ 2-piece
, is n
h re
hole
11 - Transfer box control motor -V455-

spec
es, in part or in w

t to the co
12 - Bolt, 12 Nm
13 - Seal
rrectness of i
l purpos
❑ Must lie in peripheral groove of transfer box control motor -V455-

14 - Oil drain plug, 27 Nm
nform
ercia
❑ Always renew
m
a
com
tio
15 - Oil filler plug, 27 Nm

n in
r
te o
thi
❑ Always renew
s
iva
do
r
rp
16 - Seal
um
fo
en
g
n
t.
yi Co
op py
❑ Must lie in peripheral groove of Hall sender for transfer box -G739- t. C rig
gh ht
pyri by
17 - Hall sender for transfer box -G739-
co Vo
by lksw
cted agen
Prote
AG.
5. Assembly overview - transfer box 15

Amarok 2011 ➤
18 - Bolt, 7 Nm agen
AG. Volkswagen AG d
oes
olksw not
19 - Nut, 150 Nm byV gu
ara
ed
ris nte
❑ Always renew ut
ho eo
ra
a c
❑ Unscrewing ⇒ page 21 ss
ce
e
nl
❑ Screwing on ⇒ page 22
pt
du
an
itte
y li
20 - Seal
erm
ab
ility
ot p
❑ Always renew
wit
, is n
❑ Coat with gear oil when installing
h re
hole
spec
21 - Propshaft flange
es, in part or in w
t to the co
❑ For rear propshaft.
rrectness of i
22 - Seal
❑ For propshaft flange
l purpos
❑ Renew with propshaft flange ⇒ page 20
nf
ercia
orm
m
atio
Inserting oil seal into groove in input shaft -1-
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing breather pipe

– Use pliers to move breather pipe -1- in directions of both ar‐
rows and pull out.
Driving in breather pipe

– Before driving in breather pipe -1-, coat it with Loctite -648-
locking fluid.
– Drive breather pipe to stop with thrust piece -T10203- .

Amarok 2011 ➤
6 Renewing oil seals on transfer box

Renewing input shaft seal ⇒ page 17
. Volkswagen AG
a gen AG d
Renewing outputVoshaft
lksw oil seal for front propshaft
oes
not (transfer box
gu
installed) ⇒ page
ed
by 18 ara
n
is tee
or
Renewing
au propshaft flange oil seal (transfer box installed)
th or
ac
⇒ page
ss 20
ce
e
nl
pt
du
6.1 Renewing input shaft seal
an
itte
y li
erm
ab
ility
ot p
wit
, is n
♦ Puller -T10055-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
♦ Thrust piece -T10184-

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Sealing grease -G 052 128 A1-

♦ Sheet metal screw, approx. 4 mm in diameter
Removing
– Remove transfer box ⇒ page 12 .
6. Renewing oil seals on transfer box 17

Amarok 2011 ➤
– To pull out seal, screw sheet metal screw of about 4 mm di‐

ameter -arrow- into seal.
Caution
Do not screw in sheet metal screw

agen
AG. Votoo
lkswfar
agentoAG
avoid
does damaging
bearing behind it. Volksw not
g y ua
db ran
rise tee
tho or
– Pull out seal
s au using puller -T10055- . ac
s
ce
e
nl
Installing
pt
du
an
itte
y li
– Half-fill space between sealing lip and dust lip with sealing
erm
ab
grease -G 052 128 A1- .
ility
ot p
wit
, is n
– Drive in new seal to stop with thrust piece -T10184- , being
h re
careful not to cant seal.
hole
spec
es, in part or in w
– Install transfer box ⇒ page 12 .
t to the co
– Check oil in transfer box ⇒ page 14 .
rrectness of i
6.2 Renewing output shaft oil seal for front
l purpos
propshaft (transfer box installed)

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hub grease cap puller -VW 637/2-

Amarok 2011 ➤
♦ extractor lever -VW 681-

Removing
Perform the following steps:
– Lift inner part of seal in three places using a screwdriver, offset
120°
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Pull out seal using hub grease cap puller -VW 637/2- .
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
– Pull seal out with oil seal extractor lever -VW 681- .
ion in
r
te o
Installing
thi
s
iva
do
r
rp
cum
fo
grease -G 052 128 A1- .

en
ng
t.
yi Co
op
– Position new seal on transfer box. C py
ht. rig
rig ht
by
– Push inner part of seal onto output shaft as far as possible. copy Vo
by lksw
cted agen
Prote
– Drive in new seal to stop with thrust piece -T10185- , being
AG.
careful not to cant seal.


Amarok 2011 ➤
6.3 Renewing propshaft flange oil seal (transfer box installed)
Special tools and workshop

equipment required
♦ Counterhold -3145-
♦ Thrust piece -VW 442-
♦ Removal and installing tool
-VW 459/2-
♦ Puller hooks -T20143/2-
♦ Torque wrench -V.A.G
1332-
♦ Sealing grease -G 052 128
A1-
♦ Bolts M10 x 25 (Qty. 2)
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
Always renew oil seal and propshaft flange together.

do
r
rp
cum
fo
en
ng
Removing
t.
yi Co
Cop py
t. rig
– Remove rear propshaft ⇒ page 61 . opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Unscrew nut for propshaft flange. Screwwcounterhold

gen AG
. Volksw-3145-
agen AG
does
s a
onto propshaft flange using two M10 y V x 25 bolts -arrows- in
o lk not
gu
order to counterhold. ris
ed b ara
nt ee
tho or
– Place drip tray under transfer
s a box.
u ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– If necessary, pull off propshaft flange using puller Kukko 18-1
-A- and adapter -VW 295 A- .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
– Pull out seal using puller hooks -T20143/2- . ht. rig
rig ht
py by
o Vo
Installing by c lksw
cted agen
Prote AG.
– Lightly oil outer circumference of new oil seal.
grease -G 052 128 A1- .
– Drive in new oil seal to stop with thrust piece -VW 442- and
removal and installing tool -VW 459/2- , being careful not to
cant oil seal.
– Insert new propshaft flange.

Amarok 2011 ➤
– Moisten new oil seal -1- with gear oil and insert.
– Screw on new nut for propshaft flange and tighten to 150 Nm.
Screw counterhold -3145- onto propshaft flange using two
M10 x 25 bolts -arrows- in order to counterhold.
– Install rear propshaft ⇒ page 61 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
22
co Vo
by lksw
cted
Rep. gr.34 - Controls, housing
agen
Prote AG.
Amarok 2011 ➤
7 Removing and installing Hall sender

for transfer box -G759-

Removing
– Pull off connector -1-.
AG. Volkswagen AG d
agen oes
– Place drip tray under transfer box. olksw not
V gu
d by ara
e
– Remove bolts -arrows- and pull hHall
oris sender for transfer box - nte
eo
G759- off transfer box. s aut ra
c
s
Installing
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Renew oil seal -1- if damaged. rrectne
Note
ss
♦ The drive for the Hall sender for transfer box -G759-
o
cial p
-arrow B- and the mounting for the transfer box -arrow A- are
inform
offset. The drive only fits in one position in the mounting for
mer
the transfer box.

atio
om
n
c
♦ When positioning Hall sender for transfer box -G759- , insert

i
or
n thi
centring pin into hole in transfer box -A-.

te
sd
iva
o
pr
cum
r
fo
en
ng
t.
Caution
yi Co
Cop py
t. rig
gh ht
yri
♦ It must be possible to insert Hall sender for transfer box - p by
o Vo
by c
G759- without exerting great pressure, if necessary check
lksw
cted agen
Prote
whether driver -arrow B- has been turned through 180° to
AG.
mounting -arrow A-.
– Insert Hall sender for transfer box -G759- .
7. Removing and installing Hall sender for transfer box G759 23

Amarok 2011 ➤
– Screw in bolts for Hall sender for transfer box -G759-

-arrows- and tighten to 7 Nm.
– Push on connector -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
8 Removing agen
AGand
. Volkswinstalling
agen AG
does
transfer box
control
db
yV
olksw
motor -V455- not
gu
ara
e nte
ris
Special tools
ut
ho and workshop equipment required eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing
m
at
om
io
n
c
in t
or
his
e
– Pull connector -1- off transfer box control motor -V455- .

at
do
priv
– Place drip tray under transfer box.

um
for
en
ng
t.
– Remove bolts -2- (Qty. 3) and pull transfer box control motor
yi Co
op py
-V455- off transfer box. t. C rig
gh ht
pyri by
Installing
o Vo
by c lksw
cted agen
Prote AG.
– Renew oil seal -1- if damaged.
8. Removing and installing transfer box control motor V455 25

Amarok 2011 ➤
– Screw in bolts -2- (Qty. 3) for transfer box control motor -V455-
and tighten to 12 Nm.
– Push on connector -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
39 – Final drive - rear differential

1 Rear final drive
Function of rear axle differential lock ⇒ page 28
Electrical and electronic components and their locations for rear
axle differential lock ⇒ page 29
Checking oil level in rear final drive or adding oil ⇒ page 35
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Rear final drive 27

Amarok 2011 ➤
2 Function of rear axle differential lockAG. Volkswagen A

n G do
wage es n
A mechanical rear axle differential lock is now available olks
y V as an
ot g
ua
option in the Amarok with four-wheel drive. ris
edb ran
tee
tho or
When driving offroad, rear axle differential lockau improves propul‐ ac
ss
sion on heavy ground, in particular when performing a hill start.
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All functions that assist braking are deactivated when rear axle
pt
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Rear axle differential lock can be engaged in offroad range „LOW“
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at speeds up to 30 km/h.
spec
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The differential lock is switched on or off via the rear differential
t to the co
lock switch -E121- . The differential lock control unit -J187- checks
via the CAN-Bus if the conditions to switch the rear axle differen‐
tial lock on have been fulfilled. If they have, then rear axle differ‐
rrectness of i
ential lock is activated via axle differential lock Hall sender 1 -
G460- and control solenoid -N5- .
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Refer to ⇒ Self-study programme No. 464 ; Power transmission

for more information about function.
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Refer to ⇒ Amarok owner's manual for more information and
atio
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notes on safety.
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28 Rep. gr.39 - Final drive - rear differential

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or and final drive - Edition 09.2010
au ac
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3 Electrical and electronic components
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and their locations for rear axle dif‐
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Note
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Electrical and electronic components and their locations for four-
wheel drive ⇒ page 10
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1 - Differential lock control unit

-J187-
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Remove by removing centre
m
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console ⇒ General body re‐

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c
pairs, interior; Rep. gr. 68 ;

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Compartments, covers and

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trims; Removing and installing
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centre console .
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3 - Rear differential lock switch
-E121-
❑ Rear axle differential
lock warning lamp in
transfer box operating
unit -K184-
❑ Remove by removing
selector mechanism
cover ⇒ General body
repairs, interior; Rep.
gr. 68 ; Compartments,
covers and trims; Re‐
moving and installing
centre console .
4 - Hall sender 1 for axle differ‐
ential lock -G460-
❑ With control solenoid -
N5-
❑ Location: on rear axle
3. Electrical and electronic components and their locations for rear axle differential lock 29
AG. Volkswagen AG d
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Amarok 2011 ➤ rised
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Transfer box and final driveaut - Edition 09.2010
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4 Renewing the seal for the propshaft flange of the rear axle
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equipment required hole
spec
♦ Counterhold -3145- (modi‐
es, in part or in w
t to the co
fying holes ⇒ page 30 )
♦ Torque wrench -V.A.G
1332-
rrectness of i
♦ Puller -T10055-
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♦ Socket, 34 mm -T50019-
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♦ Separating device Kukko
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♦ Bearing preload gauge - VAS 6523-

Modifying
counterhold -3145-

Amarok 2011 ➤
• Counterhold -3145- is used to loosen and tighten securing nut

for propshaft flange. Therefore, drill out both holes in counter‐
hold -3145- to dimension -a- = 10.5 mm ∅.
Note
A new counterhold -3145- with 10.5 mm ∅ holes will be supplied.
Removing:
– Remove rear wheels.
– Release handbrake.
Note
The rear axle shafts must rotate freely, otherwise back brakes off
⇒ Rep. gr. 46 .
– Unbolt propshaft from rear axle ⇒ page 61 .

– Secure propshaft to body.
Vehicle with rear axle differential lock agen
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– Drain gearbox oil via drain plug -arrow-.
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Vehicle with no rear axle differential
ss a lock ra
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– Extract gearbox oil, for example, with Used oil collection and
nl
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extraction unit -V.A.G 1782-
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Continuation for all vehicles
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Note
spec
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Observe environmental regulations for disposal.
– Check drive pinion bearing for axial play (no play permitted).
rrectness of i
l purpos
– Measure friction torque on propshaft flange with 34 mm socket

-T50019- , bearing preload gauge -VAS 6523- and cordless
power driver 12 V/1.4 Ah -VAS 5825- , for example.
nf
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Caution
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♦ To avoid incorrect measurements, measure friction torque

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♦ Perform measurements carefully and accurately to pre‐ Cop py
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vent replacement of axle casing. opyri
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♦ Do not take any actions to alter friction torque before in‐
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stalling seal on axle.
AG.
– Note reading.
4. Renewing the seal for the propshaft flange of the rear axle 31
Amarok 2011 ➤
– Remove locking device for nut -arrows-.

– Screw counter-hold tool -3145- onto propshaft flange.
– Remove securing nut using 34 mm socket -T50019- .
– Fit puller, as shown, and pull off propshaft flange.

A - Separating tool Kukko 17-2
B - Counter support Kukko 18-2
– Drive out seal -1- using a chisel. n AG. Volkswagen AG do

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Do not damage axle casing when driving out seal.
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Installing:
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spec
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– Drive in new seal flush using thrust piece -T50018-

rrectness of i
– Install new propshaft flange with new securing nut.

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Amarok 2011 ➤

– Tighten securing nut using 34 mm socket -T50019- , specified
torque 30 Nm.
– Check drive pinion bearing for axial play (no play permitted).
Note
If bearing is not without play, specified torque can be increased

in 10 Nm steps to max. 60 Nm. Renew axle casing if bearing is
not yet without play at 60 Nm.
– Remove counterhold tool -3145- .
– To align tapered roller bearings, rotate propshaft flange 15

times clockwise and 15 times anticlockwise.
– Mark position of drive pinion in relation to one edge of securing

nut. gen AG
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– Screw counter-hold tool
db
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– Turn securing nut 15° further (half of 12-point side) with 34 mm

socket -T50019- .
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4. Renewing the seal for the propshaft flange of the rear axle 33
Amarok 2011 ➤

AG. Volkswagen AG d
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pt
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– Turn securing nut 15° further (half of 12-point side) with 34 mm
ot p
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socket -T50019- .
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spec
es, in part or in w
t to the co
rrectness of i
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– Measure friction torque on propshaft flange with 34 mm socket
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-T50019- , bearing preload gauge -VAS 6523- and cordless
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power driver 12 V/1.4 Ah -VAS 5825- .

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Note
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To avoid incorrect measurements, measure friction value at ap‐

prox. 50 rpm and turning at least 5 times.
Measured friction torque must be 0.1…0.3 Nm above noted value.

Renew axle casing if value is above or below specifications.
Caution
Never set friction torque by turning securing nut back!
– Lock securing nut.

– Fill with gear oil ⇒ page 35 .
– Install propshaft ⇒ page 61 .
– Press brake pedal several times until brake shoes make con‐
tact with brake drum.

AG. Volkswagen AG d
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ut
ss a Transfer ra
c box and final drive - Edition 09.2010
ce
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pt
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5 itte Checking oil level in rear final drive or
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adding oil
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Gear oil for the rear final drive is available as a part ⇒ Electronic
hole
parts catalogue „ETKA“ .
spec
es, in part or in w
t to the co
rrectness of i
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Test precondition
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• Vehicle standing on level ground cted agen
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– Remove oil filler plug -arrow-.
The oil level is correct when the rear final drive is filled to the lower
edge of the filler hole; top up as required.
– Install oil filler plug -arrow- and tighten to 33 Nm.
5. Checking oil level in rear final drive or adding oil 35

Amarok 2011 ➤
AG. Volkswagen AG d
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39 – Final drive - front differential olksw not
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1 Front final drive ss c
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Removing and installing front final drive ⇒ page 37 itte
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Renewing oil seals on front final drive ⇒ page 41
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Renewing needle bearing for left flange shaft ⇒ page 50
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hole
Renewing bonded rubber bush on front final drive ⇒ page 52
spec
es, in part or in w
t to the co
Checking oil level in front final drive or adding oil ⇒ page 56
rrectness of i
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36 Rep. gr.39 - Final drive - front differential

Amarok 2011 ➤
2 Removing and installing

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♦ Engine and gearbox jack -V.A.G 1383 A-
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♦ Retainer -T10149-
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spec
2.1 Removing
es, in part or in w
t to the co
rrectness of i
– Remove front right wheel.
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– Remove engine/gearbox guard ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Engine/gearbox guard .
nform
ercia

m
a
com
ti
– Remove right and left drive shafts from front final drive ⇒
on in
Running gear, axles, steering; Rep. gr. 40 .
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– Unclip breather hose
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-2- at earth cable -1-.
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Illustration does not show engine to improve clarity. Prote AG.
– Carefully pull breather hose -1- off front final drive -arrow-.
Right wheel suspension must be raised in order to remove front
securing bolt for front final drive.
WARNING
Before the wheel suspension is raised, the vehicle must be

strapped to the lifting platform arms on both sides using ten‐
sioning straps -T10038- ⇒ Maintenance ; Booklet 11 Raise
vehicle.
– Turn right wheel hub until one of the wheel bolt holes is at the
top.
2. Removing and installing front final drive 37

Amarok 2011 ➤ AG. Volkswagen AG d
agen
Volksw
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– Attach support -T10149- to wheel hub thousing wheel
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bolt and eo
tighten. s au ra
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– Insert support -T10149- in engine and gearbox jack -V.A.G
nl
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1383 A- .
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WARNING
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If the vehicle is not strapped down, there is a danger that the
spec
vehicle will slip off the lifting platform!
es, in part or in w
t to the co
rrectness of i
– Raise wheel suspension using engine and gearbox jack -
l purpos
V.A.G 1383 A- until securing bolt for front final drive is acces‐
sible above transverse link -arrow-.
nf
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– Unscrew and remove securing bolt for front final drive.
orm
m
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– Lower wheel suspension again with engine and gearbox jack

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-V.A.G 1383 A- .
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– Turn steering wheel to right lock.

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– Place engine and gearbox jack -V.A.G 1383 A- under front
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– Remove support -A- and support bracket -B-.
Prote AG.
– Lower front final drive with engine and gearbox jack -V.A.G
1383 A- .
– Remove engine and gearbox jack -V.A.G 1383 A- .
A second mechanic is required to remove front final drive.
– First pull right drive shaft off front final drive, followed by left
drive shaft.
– Remove front final drive downwards.
2.2 Installing
Note
♦ Always renew securing bolts and hexagon nuts.

♦ Torque settings ⇒ Running gear, axles, steering; Rep. gr. 40 ;
Repairing front axle
– Checking oil level in front final drive ⇒ Page ⇒ page 56 .

– Turn steering wheel to right lock.
– Insert front axle drive with help from a second mechanic.
– First position left drive shaft on front final drive, followed by
right drive shaft.
– Support front final drive with engine and gearbox jack -V.A.G
1383 A- .

Amarok 2011 ➤
– Insert support bracket -B-.

– Position new securing bolts -2- and -3-, but do not tighten yet.
– Remove engine and gearbox jack -V.A.G 1383 A- .
Right wheel suspension must be raised in order to install front
securing bolt for front final drive.
WARNING
Before the wheel suspension is raised, the vehicle must be

strapped to the lifting platform arms on both sides using ten‐
sioning straps -T10038- ⇒ Maintenance ; Booklet agen AG.11 Raise
Volkswagen AG
does
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– Turn right wheel hub until one
ss of the wheel bolt holes is at the
top.
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– Attach support -T10149- to wheel hub using wheel bolt and
rm
ab
pe
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tighten.
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– Insert support -T10149- in engine and gearbox jack -V.A.G
h re
hole
1383 A- .
spec
es, in part or in w
t to the co
WARNING
If the vehicle is not strapped down, there is a danger that the
rrectness of i
vehicle will slip off the lifting platform!
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nform
mercia
– Raise wheel suspension using engine and gearbox jack -
a
com
tio
V.A.G 1383 A- until securing bolt for front final drive is acces‐
n in
sible above transverse link -arrow-.
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Prote AG.
2. Removing and installing front final drive 39

Amarok 2011 ➤
– Position new securing bolt for front final drive -1-, but do not
tighten yet.
tighten yet.
– Insert support -A-.
tighten yet.
– Position new securing bolts -6- and -7-.
– First tighten securing bolt -7- and then securing bolt -6-.
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– Tighten securing bolt for front final drive V-1-.
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– Lower wheel suspension again with risengine
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-V.A.G 1383 A- . utho eo
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– Tighten securing bolt for front final drive -4-.
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– Tighten securing bolt for front final drive -5-.
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– First tighten securing bolt -2- and then securing bolt -3-.
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– Carefully push connection nipple of breather line -1- into front
hole
spec
final drive. When doing this the connecting nipple must be in‐
es, in part or in w
serted between the raised portions of the housing and be
t to the co
horizontal -arrow-.
rrectness of i
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– Clip in breather hose -2- on earth cable -1-.

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Illustration does not show engine to improve clarity. cop Vo
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– Attach drive shafts to flange shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 .
– Install engine/gearbox guard ⇒ General body repairs, exterior;
Rep. gr. 50 ; Engine/gearbox guard .
– Install wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Fitting wheel and tyre; Fitting wheel .

AG. Volkswagen AG d
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by Vol
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Amarok 2011 ➤
d
rise nteTransfer box and final drive - Edition 09.2010
tho eo
au ra
ss c
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Renewing oil seals on front final drive
un
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Renewing oil seal for left flange shaft ⇒ page 41
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Renewing seal for right flange shaft ⇒ page 42
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Renewing input shaft seal ⇒ page 44
ole,
spec
Renewing dust cap for left flange shaft ⇒ page 47
t to the co
Renewing dust cap for right flange shaft ⇒ page 48
3.1 Renewing oil seal for left flange shaft
rrectne
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♦ Multipurpose tool -VW 771-
cial p
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– Remove front final drive ⇒ page 37 .
– Pull out left flange shaft using multipurpose tool -VW 771- .
3. Renewing oil seals on front final drive 41

Amarok 2011 ➤
– Pull out oil seal for flange shaft using multipurpose tool -VW AG. Volkswagen AG d
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– Drive in new oil seal to stop using thrust piece -T10260- .
rrectness of i
grease -G 052 128 A1- .
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– Before installing flange shaft, check dust cap for damage and
renew if necessary ⇒ page 47 .
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– Clamp flange shaft in vice using jaw protectors -B-.
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– Remove retaining ring -A- using pliers . co Vo
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– Insert new retaining ring in groove in flange shaft, being careful
not to overstretch ring.
– Drive in flange shaft using a plastic head hammer .
– Check oil in front final drive ⇒ page 56 .
– Install front final drive ⇒ page 38 .
3.2 Renewing seal for right flange shaft

♦ Multipurpose tool -VW 771-

Amarok 2011 ➤

AG. Volkswagen AG d
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pe
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es, in part or in w
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– Pull out right flange shaft using multipurpose tool -VW 771- .
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by
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– Pull out oil seal for flange shaft using multipurpose tool -VW
771- .
– Drive in new oil seal to stop using thrust piece -T10259- .

grease -G 052 128 A1- .

Amarok 2011 ➤
Transfer box and final drive - Edition 09.2010 AG. Volkswagen AG d
agen oes
olksw not
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– Before installing flange shaft, check dust cap -arrow- for dam‐ed by ara
nte
age and renew if necessary ⇒ page 48 . horis
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– Clamp flange shaft in vice using jaw protectors -B-.
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– Remove retaining ring -A- using pliers .

– Insert new retaining ring in groove in flange shaft, being careful
nform
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not to overstretch ring.

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at
– Drive in flange shaft using a plastic head hammer .
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3.3 Renewing input shaft seal
by c lksw
cted agen
Prote AG.

♦ Puller -T10055-

♦ Thrust piece -T10430/1-
♦ 2 self-tapping screws with 4 mm diameter
– Remove front propshaft ⇒ page 59

Amarok 2011 ➤
– Pull off oil seal -1- and retaining ring -2-.

– To be able to screw self-tapping screws -arrows- into sealing
cover, first use drift to punch 2 holes in sealing cover.
– Screw in self-tapping screws with 4 mm diameter.

– Pull out dust cap using puller -T10055- .
– Use a drift to punch 2 holes in oil seal.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
– Screw in self-tapping screws with 4 mm diameter.
ility
ot p
wit
is n
h re
ole,
Note spec
t to the co
Do not screw in sheet metal screw too far to avoid damaging
bearing behind it.
rrectne
– Pull out seal using puller -T10055- .

– For new seal, half-fill space between sealing lip and dust lip
ss
with sealing grease -G 052 128 A1- .

o
cial p
f inform
– Mask off splines of stub shaft with adhesive tape.

mer
atio
– Push new oil seal as far as oil seal seat on final drive.
om
n
c
i
or
n thi
e
– Drive in seal to stop with thrust piece -T10430- , being careful

t
sd
va
not to cant seal.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Drive on new dust cap with thrust piece -T10430/1- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Insert new oil seal -1- and new retaining ring -2-.
ility
ot p
wit
, is n
h re
hole
– Install front propshaft ⇒ page 60
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
3.4 Renewing dust cap for left flange shaft

equipment required
♦ Press tool -VW 412-
♦ Thrust piece -VW 432-
♦ Support rails -VW 457-
AG . Volkswagen AG
♦ Pulling ring -2003/3-
ksw
agen does
not
ol
yV gu
♦ Assembly sed b tool -3301- ara
nte
ri
ho eo
♦ Sealing
aut grease -G 052 128 ra
c
ss
A1-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ -3- - Separating device Kukko 17-2
• Flange shaft removed, removing ⇒ page 41

Amarok 2011 ➤

– Press dust cap -B- off flange shaft.
– Press on dust cap for flange shaft -A-.
Note
Position sleeve -3301/3- with notch -arrow- facing dust cap -A-.
3.5 Renewing dust cap for right flange shaft

♦ Assembly tool -3301-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Thrust piece -3456-

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
♦ -3- - Separating device Kukko 17-2
• Flange shaft removed, removing ⇒ page 42

– Press dust cap -B- off flange shaft.
lkswage es n
o ot g
yV ua
– Drive on new dust cap for flange
ir se
d shaft -A- using thrust piece
b ran
-3456- and sleeve -3301/3-
uth .
o tee
or
a ac
ss
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
Position sleeve -3301/3- with notch facing dust cap -A-.

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011 ➤
4 Renewing needle bearing for left flange shaft

equipment required
♦ Press tool -30 - 505-
♦ Press tool -30 - 506 B-
♦ Internal puller Kukko 21-6
-1-
♦ Counter support Kukko
22-2 -4-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole

spec
es, in part or in w

t to the co
– Remove left flange shaft and oil seal ⇒ page 41 .

rrectness of i
– Pull out left flange shaft needle bearing.

l purpos
A - Internal puller Kukko 21-6

B - Counter support Kukko 22-2
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Drive in needle bearing for left flange shaft -A- to stop.

– Install left flange shaft and oil seal ⇒ page 41 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Renewing needle bearing for left flange shaft 51

Amarok 2011 ➤
wage 09.2010
Transfer box and final drive -VEdition es n
olks ot gu
by ara
ed nte
oris eo
th
5 Renewingssbonded rubber bush on au ra
c
front final drive
ce
le
un
pt
an
d
itte
y li
Pulling bonded rubber bush on rear housing out and in erm
ab
⇒ page 52 .
ility
ot p
wit
is n
Pulling bonded rubber bush on front housing out and in
h re
ole,
⇒ page 53 .
spec
Pulling bonded rubber bush on left of housing out and in
t to the co
⇒ page 54 .
rrectne
equipment required
ss
♦ Assembly tool -T10435-
o
cial p
f in
♦ Assembly tool -T10254-
form
mer
atio
♦ Foot pump -VAS 6179-
om
n
c
i
♦ Hydraulic press -VAS
or
n thi
e
6178-
t
sd
iva
o
pr
c
♦ Tube -30 - 14-
um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5.1 Pulling bonded rubber bush on rear

housing out and in
Pulling out
– Set foot pump -VAS 6179- to lowest setting.

Amarok 2011 ➤
– Pulling out bonded rubber bush.
Note
Washer -A- from assembly tool -T10435-
Pulling in
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– Position bonded rubber bush in installation position
ss on front c
final drive.
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
h re
Corners and small recesses of bonded rubber bush -arrows A-
hole
must be at right angles to final drive.
spec
es, in part or in w
t to the co
– Mark installation position -arrow B- of bonded rubber bush.
rrectness of i
l purpos
– Pull in bonded rubber bush until dimension -a- ⇒ page 53 is

reached.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Pull-in depth for bonded rubber bush

Dimension -a- = 47.4 mm
5.2 Pulling bonded rubber bush out of and

into front of housing
Pulling out
5. Renewing bonded rubber bush on front final drive 53

Amarok 2011 ➤
Note
Pulling in
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Position bonded rubber bush in installation position
utho
on front eo
ra
a
final drive. ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
Small recesses of bonded rubber bush -arrows B- must be at right
wit
, is n
angles to final drive.
h re
hole
spec
es, in part or in w
– Mark installation position -arrow A- of bonded rubber bush.
t to the co
rrectness of i
– Pull in bonded rubber bush until it is centred in front final drive
l purpos
housing.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.3 Pulling bonded rubber bush on left of
housing out and in
Pulling out
Note
Pulling in

Amarok 2011 ➤
– Position bonded rubber bush in installation position on left of

final drive.
Note
Small recesses of bonded rubber bush -arrows B- must be at right

angles to final drive.
– Mark installation position -arrow A- of bonded rubber bush.
– Pull in bonded rubber bush until it is centred in housing on left

of final drive.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Renewing bonded rubber bush on front final drive 55

Amarok 2011 ➤
6 Checking oil level in front final drive

or adding oil
Gear oil for the front final drive is available as a part ⇒ Electronic
parts catalogue „ETKA“ .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Ring ratchet spanner, 13 mm AF -T10384-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
♦ Bit -T50039-
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Front final drive has a fill-for-life oil fill. It is only necessary to

check oil level or to top up oil after renewal of oil seal or if final
drive is replaced. Due to poor accessibility of oil filler plug when
installed, oil level should be checked or oil should be replen‐
ished prior to installation.
♦ The special tool indicated is to be used.
Test precondition
• Front final drive in installation position

Amarok 2011 ➤

– Remove oil filler plug -arrow-.
The oil level is correct when the front final drive is filled to the lower
– Install oil filler plug -arrow- and tighten to 35 Nm.
With the component in its installed position
– Unscrew the oil filler plug -arrow- with a combination of ring
ratchet spanner, 13 mm AF, -T10384- and bit -T50039- .
The oil level is correct when the front final drive is filled to the lower
– If necessary, replenish oil via the breather hose, using a stand‐
ard funnel ⇒ page 37 .
WARNING
Danger of burning.
Exhaust system can be hot.
Allow exhaust system to cool down before replenishing oil.
– Screw in the oil filler plug -arrow- with a combination of ring

ratchet spanner, 13 mm AF, -T10384- and bit -T50039- and
tighten to 35 Nm. . Volkswage AG n AG d
agen oes
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Checking oil level in front final drive or adding oil 57

Amarok 2011 ➤
39 – Final drive - differential

1 Propshafts
Note
♦ If propshaft is disconnected only from the rear axle, the prop‐

shaft must be raised and secured or supported.
AG. Volkswagen AG d
agen
♦ Keep propshaft straight; store and transport fully extended
Vol
ksw on‐
oes
not
ly. ed
by gu
ara
nte
oris eo
♦ No repairs can be made to the propshaft. auth ra
ss c
ce
e
nl
Assembly overview - propshaft ⇒ page 58
pt
du
an
itte
y li
Removing and installing rear propshaft ⇒ page 61
erm
ab
ility
ot p
Removing and installing front propshaft ⇒ page 59
wit
, is n
h re
1.1 Assembly overview - propshafts
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ No repairs can be made to the propshaft.
l purpos
♦ Illustration shows propshafts of four-wheel drive.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
58 Rep. gr.39 - Final drive - differential

Amarok 2011 ➤
1 - Seal
❑ On front final drive
❑ Grease with drive shaft
grease -G 052 738 A2-
2 - Retaining ring
❑ On front final drive
❑ Renew
3 - Front propshaft
❑ Four-wheel drive only
⇒ page 59
❑ Markings on pin of front
final drive and front
propshaft must be in
alignment
4 - Retaining ring
❑ Renew
❑ Grease with drive shaft
grease -G 052 738 A2-
5 - Seal
6 - Transfer box
❑ Four-wheel drive only
7 - Bolt, 50 Nm + turn 90° fur‐
ther
❑ Renew
8 - Rear propshaft
AG. Volkswagen AG d
❑ Removing and lkswinstalling
agen oes
not
⇒ paged 61
by Vo gu
a
e ran
ris tee
9 - Hexagon
tho nut, 20 Nm and then turn 90° further or
au ac
❑ sRenew
s
ce
e
nl
pt
10 - Centre bearing
du
an
itte
y li
❑ Installing intermediate bearing free of tension ⇒ page 63

erm
ab
ility
ot p
wit
, is n
h re
1.2 Removing and installing front propshaft

hole
spec
es, in part or in w

t to the co
♦ Counterhold -3415-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
♦ Grease for drive shafts -G 052 738 A2-
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
59
AG.
1. Propshafts
Amarok 2011 ➤

Removing
Before removing, mark positions of all parts relative to each other.
Reinstall in the same position otherwise imbalance will be exces‐
sive, the mountings could be damaged causing rumbling noises.
– Remove engine/gearbox guard ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Engine/gearbox guard .
– Check if there are markings (paint spots) -A- on front propshaft
and on front final drive.
– If these markings are not present, then mark position of prop‐
shaft flange in relation to front final drive with paint.
– Prise front propshaft -1- off final drive using assembly lever.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Push front propshaft off transfer box using counterhold
hole
spec
-3415- .
es, in part or in w
t to the co
– Remove front propshaft.
Installing
.
rrectness of i

l purpos
following:
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011 ➤
– Renew oil seals -1- if damaged.

– Renew retaining rings -2-.
– Grease splines of shafts and oil seals -1- with drive shaft
grease -G 052 738 A2- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
– Markings -A- must be aligned with one another as far as pos‐
pe
ility
ot
sible.
wit
, is n
h re
– Position front propshaft on front final drive.
hole
spec
es, in part or in w
t to the co
Caution
Wear protective gloves!
rrectness of i
l purpos
nform
mercia
a
com
ti
– Then push front propshaft -1- onto shaft forcefully by hand until
on in
it engages.
r
te o
thi
s
iva
– Pull on front propshaft to check propshaft has engaged cor‐

do
r
rp
rectly.
um
fo
en
ng
t.
yi
– Position front propshaft on transfer box.
Co
Cop py
t. rig
gh
– Push front propshaft onto shaft until it engages.
ht
pyri by
Vo
co lksw
by
– Pull on front propshaft to check propshaft has engaged cor‐
cted agen
Prote AG.
rectly.
– Install engine/gearbox guard ⇒ General body repairs, exterior;
Rep. gr. 50 ; Engine/gearbox guard .
1.3 Removing and installing rear propshaft

1. Propshafts 61
Amarok 2011 ➤
♦ Brake pedal actuator -V.A.G 1869/2- (vehicles with rear-wheel

drive)
♦ Counterhold -T10172- (vehicles with four-wheel drive)
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
Note s
ce
le
un
pt
an
d
♦ If possible, use a twin pillar lifting platform when working on

itte
y li
rm
the propshaft.
ab
pe
ility
ot
♦ Remove and install propshaft with the help of a second me‐

wit
, is n
chanic.
h re
hole
spec
♦ Before removing, mark positions of all parts relative to each

es, in part or in w
other. Reinstall in the same position otherwise imbalance will

t to the co
be excessive, the mountings could be damaged causing rum‐

bling noises.
rrectness of i
♦ Keep propshaft straight; store and transport fully extended on‐

ly.
l purpos
♦ Do not let propshaft »hang« during removal; always support

it.
nform
ercia
♦ Always pull propshaft from or push it onto drive flange hori‐

m
a
com
zontally .
ion in
r
te o
thi
s

iva
do
r
rp
cum
Removing
fo
en
ng
t.
yi Co
Vehicles with rear-wheel drive Cop py
t. rig
gh ht
yri
– Fit brake pedal actuator -V.A.G 1869/2- . p by
o Vo
by c lksw
cted agen
– Raise vehicle ⇒ Maintenance ; Booklet 11 . Prote AG.
– Unscrew securing bolts for propshaft on propshaft flanges, but

do not remove them yet.
Vehicles with four-wheel drive

Amarok 2011 ➤
– Unscrew securing bolts for propshaft on propshaft flanges, but

do not remove them yet. Brace using counterhold -T10172- .
Continuation for all vehicles
Caution
To prevent noises due to imbalance, mark the position of the

propshaft relative to the flanges.
– Mark position of propshaft in relation to propshaft flanges.
– Unscrew hexagon nuts for centre bearing -arrows-.
Note
A second mechanic is required for the further removal of the

propshaft.
Caution
To avoid damaging the protective boot in the centre bearing,

remove, store and install the propshaft swith
wagethe
n AGjoint as straight
. Volkswagen AG
does
as possible. by
Vol
k not
gu
ara
ed nte
ris
tho e or
au ac
– Unscrew propshaft at propshaft
ss flanges and remove propshaft
with joint positioned as straight as possible.
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
ility

ot p
following:
wit
, is n
h re
hole
– Install all parts which were marked in relation to each other in

spec
their original positions.

es, in part or in w
t to the co
– Install propshaft with new bolts. Torque setting ⇒ page 58

Installing intermediate bearing free of tension
rrectness of i
• All propshaft bolts are tightened.

l purpos
– Align intermediate bearing in its elongated holes so that nei‐

ther propshaft nor intermediate bearing is under tension.
nform
ercia
– Tighten new hexagon nuts. Torque setting ⇒ page 58

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Propshafts 63

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Transfer Box and Final Drive PDF

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Transfer box and final drive

Service Department. Technical Information

39 - Final drive - differential

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg D3E8028924F

5 Four-wheel drive - notes on performance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Checking oil level in transfer box or adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 Renewing oil seals on transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 Removing and installing transfer box control motor V455 . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2 Function of rear axle differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.1 Pulling bonded rubber bush on rear housing out and in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1 - Front final drive

3 - From manual gearbox

❑ With reduction gearing

❑ Changing between on‐

road range „HIGH“ and

offroad range „LOW“ is

6 - Rear final drive

❑ Optionally with rear axle

1. Overview - four-wheel drive power train 1

2 Transfer box identification

2.1 Location on transfer

Identifica‐ Day Month Year (2009)

tion code of manufac‐

Additional data depend on manufacture.

Transfer box 0C7

2 Rep. gr.00 - Technical data

3 Identifying front final drive

3.1 Location on front final drive

Codes -arrow- and manufacturing data for front final drive

Identifica‐ Day Month Year (2010)

3.2 Identification code, assembly allocation, capacities

3. Identifying front final drive 3

4 Rear final drive

4.1 Identification code, assembly allocation, ratios, capacities

♦ Allocation to corresponding vehicle

4 Rep. gr.00 - Technical data

5. Four-wheel drive - notes on performance test 5

6 General repair notes

wax and grease.

♦ Capacity of transfer box ⇒ page 2 .

♦ When changing front final drive, top up with gear oil

When changing rear axle, top up with gear oil ⇒ page 35 .

6.1.3 Seals and sealing rings

6.1.4 Locking devices

6 Rep. gr.00 - Technical data

6.1.5 Nuts and bolts

6. General repair notes 7

♦ Vehicle diagnosis and service information system -VAS 5052

To avoid accident risks, proceed as follows during measuring

and test drives:

♦ Use only vehicle diagnosis, testing and information sys‐

tem -VAS 5051B- or vehicle diagnosis and service infor‐

mation system -VAS 5052 A- to read measured value

blocks. Always secure device on rear seat and have a

second person operate it from there.

8 Rep. gr.34 - Controls, housing

– With ignition switched off, connect vehicle diagnosis, testing

Wait until tester has read all control units in vehicle.

– Press Goto button and select Select function/compo-