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Service

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Amarok 2011

Transfer box and final drive


Edition 05.2013

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Workshop Manual

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AG. Volkswagen AG d
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - Technical data
39 - Final drive - rear differential
39 - Final drive - front differential
39 - Final drive - differential

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AG. Volkswagen AG d
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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.
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AG.

All rights reserved.


No reproduction without prior agreement from publisher.
Copyright 2013 Volkswagen AG, Wolfsburg

D3E8028924F

Amarok 2011
Transfer box and final drive - Edition 05.2013

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification of gearbox g.en. A. G. ..V.o.lk.sw. a. g.e.n.A.G.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a
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lksw
Identification of final
. . . . . . . . . . . . . . . .s n. o.t .gu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vodrive
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Technical data
ris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .n.tee. . . . . . . . . . . . . . . . . . . . . . . . . . .
o
h
ut rear final drive - engine/capacities . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . . . .
Allocations aof
c
s
Allocation of front final drive - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allocation of transfer box - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Allocation of rear axle - engine/capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - power transmission - four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
2
2.1
2.2
2.3
2.4
2.5
3
3.1
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing drive pinion and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking backlash and contact pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulling tapered roller bearing for drive pinion off and pressing it on . . . . . . . . . . . . . . . . . .
Pulling tapered roller bearing for differential off and pressing it on . . . . . . . . . . . . . . . . . .
Overview of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining shims for crown wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining shims for drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing propshaft flange seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing propshaft flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear-axle differential lock components and their locations . . . . . . . . . . . . . . . . . . . . . . . .
Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - flexible coupling for propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - Tirsan propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - Dana propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling and assembling propshaft intermediate bearing, Dana propshaft . . . . . . . .
Dismantling and assembling propshaft intermediate bearing, Tirsan propshaft . . . . . . . .
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking gear oil level in bevel box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
2
2.1
2.2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
4.1

Contents

1
1
1
1
3
3
3
3
4
4
6
6
7
7
7
7
7
8
8
8

9
10
10
13
13
14
24
26
27
30
32
34
35
36
39
43
49
51
51
51
53
53
54
55
56
57
60
63
67
67

Amarok 2011
Transfer box and final drive - Edition 05.2013

39 - Final drive - front differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68


Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Volkswage
Removing and installing front final drive . . . . .ks.w.a.ge. n. A. G. . . . . . . . .n.A.G.d.oe. s.n. . . . . . . . . . . . . .
l
ot
o
V
Renewing bonded rubber bush on rear ofdfinal
by drive . . . . . . . . . . . . . . . . . . g.u.ar. . . . . . . . . .
a
e
s
ri of final drive . . . . . . . . . . . . . . . . . . . . . n.te.e. . . . . . .
Renewing bonded rubber bush on front
tho
or
u
Renewing bonded rubber on left ofss afinal drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.c . . . .
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking level of gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing left flange shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing oil seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing dust cap for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing dust cap for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing needle bearing for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68
68
68
73
75
77
79
79
81
81
82
84
87
88
90

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1
1.1
1.2
1.3
1.4
1.5
2
2.1
3
3.1
3.2
3.3
3.4
3.5
3.6

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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Contents

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ii

Transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing transfer box control unit J646 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing transfer box Hall sender G759 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing transfer box control motor V455 . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing propshaft flange seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

do
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3

92
92
94
95
97
99
99
100
102
102
103
105

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Technical data
Identification

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(VRL005429; Edition 05.2013)


1.1 Identification of gearbox, page 1
1.2 Identification of final drive, page 1

1.1

Amarok 2011
drive - Edition 05.2013

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00

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Transfer
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Identification of gearbox

A reduction gearing is integrated into the transfer box.


Location on transfer box -arrow-.

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Production date -arrow A- and identification code -arrow B- of


transfer box
Example

LEP
I
I
Identifica
tion code

09
I
I
Day

12
I
I
Month

09
I
I
Year (2009)
of manufac
ture

Additional data depend on manufacture.

1.2

Identification of final drive

Location on front final drive -arrow-

1. Identification

Amarok 2011
Transfer box and final drive - Edition 05.2013
Codes -arrow- and manufacturing data for front final drive
Identification
code
MGY

Year

Day

Serial number

xxx

xxxx

Additional data depend on manufacture.

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Rep. gr.00 - Technical data

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Amarok 2011
Transfer box and final drive - Edition 05.2013

Technical data

2.1 Allocation of rear final drive - engine/capacities,


page 3
2.2 Allocation of front final drive - engine/capacities,
page 3
2.3 Allocation of transfer box - engine/capacities, page 3
2.4 Allocation of rear axle - engine/capacities, page 4
2.5 Calculation of gear ratios, page 4

2.1

Allocation of rear final drive - engine/capacities

Rear final drive


Identification code

0CC
MQA

Allocation

Model
Engine
Final drive

Ratio
Capacity

Amarok 2011
2.0 l - 120 kW
i = 4.1
2.0 l1)

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The following
nteparts
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2.0 l1)

cata

Specification of gear oil

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Amarok 2011
2.0 l - 120 kW
i = 4.1

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Allocation to corresponding vehicle

2.2

MQB

Allocation of front final drive - engine/capacities

Front final drive


Identification code
Allocation

0C1
MQL

Model
Engine

Capacity

Amarok 2011
2.0 l - 120 kW
0.8 l

The following data can be found in the Electronic parts cata


logue ETKA .
Allocation to corresponding vehicle by engine code

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Allocation of transfer box - engine/capacities


AG.

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Identification code
Allocation

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Specification of gear oil

0C7
LEP

Model
Engine

Amarok 2011
2.0 l - 120 kW
1.25 l

0C7
NHY
Amarok 2011
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
2. Technical data

Amarok 2011
Transfer box and final drive - Edition 05.2013
Specification of gear oil

Allocation of rear axle - engine/capaci


ties
2H0.500.025. 2H0.500.025. 2H0.500.025.
AH
AJ
AF
2H0.501.011. 2H0.501.011. 2H0.501.011.
AH
AJ
AF

Standard

2.0 l
120 kW TDI

2.0 l 11 kW
petrol
2.0 l 90 kW
TDI
2.1 l 0.1 l

2.1 l 0.1 l

2.1 l 0.1 l

VW part num
ber
(with brake)
VW part num
ber
(without brake)

2H0.500.025. 2H0.500.029. 2H0.500.029.


AG
D
E
2H0.501.011. 2H0.501.011. 2H0.501.011.
AG
AP
AQ
40094736

40101793

NAL

NAM

Prote
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37 : 10 = 3.70 37 : 10 = 3.70
Standard

Lockable

2.0 l
132 kW TDI

2.0 l
132 kW TDI

2.1 l 0.1 l

2.1 l 0.1 l

1)

Data shown on axle type plate.

2)

If the oil was merely drained, the capacity is 2.0 l.

3) For current part numbers and codes refer to

Catalogue (ETKA) .

Calculation of gear ratios

Example:

41 : 10 = 4.10
Z2 : Z1 = i 1)

Rep. gr.00 - Technical data

Electronic Parts

AG.

Manufacturer's 40073723
part number
Rear-axle
MPZ
code
43 : 10 = 4.30
Gear ratio 1)
Z2 : Z1 = i
Differential
Lockable
type
Engine alloca 2.0 l 118 kW
tion
petrol
2.0 l 90 kW
TDI
Capacity (dry 2.1 l 0.1 l
axle) 2)

rrectness of i
t to the co
nform
spec
at
i
h re
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his

Lockable

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41 : 10 = 4.10 43 : 10 = 4.30

Capacity (dry
axle) 2)

2.5

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Manufacturer's 40073724
part number
Rear-axle
MQA
code
41 : 10 = 4.10
Gear ratio 1)
Z2 : Z1 = i
Differential
Standard
type
Engine alloca 2.0 l
tion
120 kW TDI

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40073722
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VW part num
ber
(with brake)
VW part num
ber
(without brake)

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2.4

Amarok 2011
Transfer box and final drive - Edition 05.2013
1)

Z1 = no. of teeth on drive gear


Z2 = no. of teeth on driven gear
i = gear ratio

rrectness of i
t to the co
nform
spec
at
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2. Technical data

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Overview - power transmission

3.1

rrectness of i
t to the co
nf
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r
m
spec
atio
h re
n in
wit

3.1 Overview - power transmission - four-wheel drive,


page 6

Overview - power transmission - four-wheel drive

1 - Front final drive


Removing and installing
page 68 .
2 - Front propshaft
Removing and installing
page 56 .

Rep. gr.00 - Technical data

Prote
cted
by

AG.

6 - Rear final drive


Optionally with rear axle
differential lock
page 51

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5 - Rear propshaft
Removing and installing
page 57 .

c
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4 - Transfer box
With reduction gearing
Changing between on
road range HIGH and
offroad range LOW is
performed using run
ning gear programme
switch - E631 page 94
Removing and installing
page 95 .

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3 - From manual gearbox

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Amarok 2011
Transfer box and final drive - Edition 05.2013

Amarok 2011
Transfer
box
and
final
drive
Edition 05.2013
. Volkswage

Repair instructions
es, in part or in w
l purpos
hole
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m
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4.1 Gearbox, page 7

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4.2 Rear axle, page 7

4.3 Seals and sealing rings, page 7

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

4.4 Locking devices, page 7


4.5 Nuts and bolts, page 8
4.6 Bearing, page 8
4.7 Shims, page 8

4.1

Gearbox

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.

AG.

Prote
cted
by

When installing mounting brackets or waxed components,


clean the contact surfaces. Contact surfaces must be free of
wax and grease.

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Always renew retaining rings for front propshaft on transfer


box and front final drive.

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Co
t.

When installing the transfer box, ensure that the dowel sleeves
between the gearbox and transfer box are correctly installed.

thi
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en

A number of generally applicable instructions for the various re


pair procedures which were previously repeated at numerous
places in the workshop manual are summarised here. They apply
to this workshop manual.

Allocate bolts and other components using Electronic parts


catalogue (ETKA) .
Capacity of transfer box page 3 .
Capacity of front final drive page 3 .

4.2

Rear axle

When a dry, clean rear axle is filled for the first time or refilled
(new or completely cleaned rear axle) the oil capacity is 2.1 l
0.1 l.
If a used rear axle is filled after the oil was merely drained, the
capacity is 2.0 l 0.1 l.
Axle must be in horizontal position while oil is drained.

4.3

Seals and sealing rings

Thoroughly clean joint surfaces.


Apply sealing paste Electronic Parts Catalogue (ETKA) to
drive pinion splines or propshaft flange. Spread a 2-3 mm
bead around drive pinion teeth.
Renew O-rings if damaged.
Renew cover seal.
Renew both pinion seals if leaking.

4.4

Locking devices

Do not overstretch retaining rings.

4. Repair instructions

Amarok 2011
Transfer box and final drive - Edition 05.2013
Retaining rings must locate properly in grooves. With opening
towards floor.
Renew compression sleeve.

4.5

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.
Always renew M14 brake bolts.
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.

4.6

Bearing

Note the installation position of the sealed wheel bearings: the


flat metal oil seal facing the wheel and the rubber oil seal facinggen AG. Volkswagen AG d
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the axle.
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Do not interchange the inner and outer races of same
size
ris
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bearings.
au

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hole
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n

Shims

Install only flawless shims.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Measure shims at several points with a micrometer. The var


ious thicknesses make it possible to achieve the exact shim
thickness required.
Check for burrs and damage.

or
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4.7

ss

Note the shims' location. There must be no gap between the


shim and the adjacent surface.

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Rep. gr.00 - Technical data

do
c
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en

Amarok 2011
Transfer box and final drive - Edition 05.2013

Final drive - rear differential

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
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hole
ercia
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39

1. Final drive

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AG.

Prote
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by

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Amarok 2011
Transfer box and final drive - Edition 05.2013

Final drive

1.1 Assembly overview - final drive, page 10


1.2 Assembly overview - differential, page 13
1.3 Removing and installing actuator, page 13
1.4 Removing and installing drive pinion and differential, page
14
1.5 Dismantling and assembling differential, page 24
Volkswagen AG

AG. 26
genpage
1.6 Removing and installing crown wheel,
swa

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ing it on, page 30

1.9 Pulling tapered roller bearing for differential off and press
ing it on, page 32

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

1.10 Overview of shims, page 34

ility
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does
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1.7 Checking backlash and contact
pattern,
page
27
e
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ris
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ra
1.8 Pulling tapered roller bearing
for
drive
pinion
off
and
press
a
c
ss

k
Vol

1.11 Adjustment overview, page 35


1.12 Determining shims for crown wheel, page 36
1.13 Determining shims for drive pinion, page 39
1.14 Renewing propshaft flange seal, page 43
1.15 Repairing propshaft flange, page 49

1.1

Assembly overview - final drive

Prote
cted
by

3 - Bolt
Renew after removal
Apply locking fluid - D
185 410 A2- before
starting bolt.
44 Nm
4 - Seal
Renew after removal
5 - Bolt
85 Nm

10

Rep. gr.39 - Final drive - rear differential

AG.

Repair work which may


affect the function of the
tachograph must always
be carried out in certified
workshops.

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Caution

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2 - Final drive cover


Vehicles with a digital
tachograph have a sen
sor mounting on the
cover page 18 .

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en

1 - Oil filler plug


Renew after removal
33 Nm

Amarok 2011
Transfer box and final drive - Edition 05.2013
6 - Bearing bracket
Paired with axle beam
Mark installation position
7 - Shim
For adjusting crown wheel.
Installation position: chamfered side faces axle tube.
Determining shims page 36 .
8 - Outer ring
For tapered roller bearing
9 - Tapered roller bearing
Pulling off and pressing on page 32 .
10 - Retaining ring
11 - Bolt
Left-hand thread
140 Nm
12 - Differential
Removing and installing page 14 .
Dismantling page 24
. Volkswagen AG
gen AG
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13 - Crown wheel
yV
db
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ris
Removing and installing
ho page 26
ut
a
Determining shims
ss page 36 .

14 - Actuator

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Caution

Handle actuator with ex


treme caution and do not
strike it against any other
object.
Risk of damage to the
sensor.
Removing and installing page 13
15 - Oil drain plug
Renew after removal
33 Nm

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18 - Propshaft flange
Removing and installing page 43 .

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17 - Flange nut
Renew after removal

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en

16 - Axle beam
Removing and installing Rep. gr. 42 ; Rear axle; Removing and installing rear axle .

19 - Dust cap
20 - Sealing sleeve
Renew after removal
Removing and installing page 43 .
21 - Seal
Renew after removal

1. Final drive

11

Amarok 2011
Transfer box and final drive - Edition 05.2013
Caution

If the seal is renewed,


the friction torque must
be determined before
starting repair work
page 44 .
If the friction torque has
not been determined be
fore removal, the com
pression sleeve and the
drive pinion bearings will
have to be renewed.
Removing and installing page 43 .

28 - Drive pinion
Removing and installing page 14 .

es, in part or in w
l purpos
hole
ercia
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27 - Shim
For adjusting drive pinion
Determining shims page 39 .

Prote
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by c
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Rep. gr.39 - Final drive - rear differential

do
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12

AG.

26 - Inner tapered roller bearing


Pulling off and pressing on page 30 .

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25 - Compression sleeve
Remove to renew drive pinion.
Renewing page 20

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

24 - Outer ring
For inner tapered roller bearing
Remove and install using drift - 3138- .

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23 - Outer ring
For outer tapered roller bearing
Remove and install using drift - 3138- .

AG. Volkswagen AG d
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22 - Outer tapered roller bearing


Remove to renew drive pinion.

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.2

Assembly overview - differential

1 - Thrust washer
2 - Differential pinion
Large
3 - Differential pinion
Small
4 - Thrust washer
5 - Pin
6 - Differential pinion
Large
7 - Return spring
8 - Thrust washer
Only in vehicles with dif
ferential lock.
9 - Selector fork
Only in vehicles with dif
ferential lock.
10 - Guide ring
Renew after removal
Will be destroyed during
removal and installation
AG. Volkswagen AG d
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process.
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Only in vehicles with dif ised
nte
r
o
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ferential lock.
h
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ra
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sa

Removing and installing actuator

Note

r
fo
ng

On vehicles with differential lock the guide ring may be damaged


during the removal of the actuator Item 10 (page 13) . Check
the guide ring for damage after the actuator has been removed.
For this, the differential must be dismantled page 24 .
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Prote
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by
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Remove drive pinion and differential page 14 .

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Removing

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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1.3

urposes, in part or in wh
ole,
cial p
is n
mer
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or
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a
itte
v
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p

un
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s
11 - Securing pin
Renew after removal
Will be destroyed during
removal and installation
process.
Remains of pin remain
in differential housing.
The depth of the hole allows for shearing off the pin twice as well as for two remnants to remain in the
hole (new version). In case of the old versions the securing pin must be removed completely.

1. Final drive

13

AG.

un
le

ility
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Amarok 2011
Transfer box and final

n AG. Volkswagen AG do
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ran
ir se
tee
o
h
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u
ac
a
drive
ss - Edition 05.2013

Note

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
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ot
com

pe
rm
itte
d

Remove outer race -arrow- from tapered roller bearing -1- on


left and right.

The tapered roller bearing on the actuator end will be damaged


when being removed and must be renewed.
Press tapered roller bearing on actuator end off differential
page 32 .

Prote
cted
by

Installing
Install in reverse order of removal, observing the following:
Installing drive pinion and differential page 14
Specified torques
1.1 Assembly overview - final drive, page 10

1.4

Removing and installing drive pinion


and differential
Note

The final drive gear set can be removed and installed with axle

installed.

The final drive gear set (drive pinion and crown wheel) may

only be replaced as a complete unit.

14

Rep. gr.39 - Final drive - rear differential

AG.

Carefully remove actuator -arrow- from differential.

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Risk of damage to the sensor.

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Handle actuator with extreme caution and do not strike it


against any other object.

do
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en

Caution

r
te o
iva
r
rp
fo
g
n

Remove circlip -1- of actuator with a screwdriver or circlip pli


ers.

Amarok 2011
Transfer box and final drive - Edition 05.2013
Special tools and workshop
equipment required
Thrust piece - VW 554 Tube - VW 519 Thrust piece - VW 432-

Drift - 3138-

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
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Counter-hold tool - 3145(modify holes on old ver


sion page 44 )

AG. Volkswagen AG d
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Torque wrench - VAS


5088-

1. Final drive

15

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AG.

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AG. Volkswagen AG d
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Amarok 2011
by
ara
d
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nte
s
i
r
Transfer box and tfinal
drive - Edition 05.2013
eo
ho
u
ra
a
c
s
s

Counter support Kukko


18-2
Separating tool Kukko 17-2
Fitting tool - T50023 Thrust piece - VW 433 Thrust piece - T50048/1-

AG.

Rep. gr.39 - Final drive - rear differential

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Prote
cted
by c
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16

ht
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Co
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r
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ng

Thrust piece - T50048/2-

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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um
en

urposes, in part or in wh
ole,
cial p
is n
mer
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or
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a
itte
v
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p

un
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Special tools and workshop


equipment required

2011
Transfer box and final drive - Edition 05.2013

pe
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un
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AG. Volkswagen AG d
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ac
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s
s

Support device - T10323-

rrectness of i
t to the co
nform
spec
a
t
i
h re
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n in
wit
thi
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Thrust piece - T50018-

Socket 32 mm - T10209 Expander - T50021- (renew


washers and M8 securing
bolts with new bolts with
property class 12.9 before
each installation)
Torque wrench - V.A.G
1331-

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Torque wrench - V.A.G


1332-

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Loctite 565
Removing differential
Drain gear oil Item 15 (page 11) .
Remove rear axle shafts Rear suspension; Rep. gr. 42 ;
Rear axle; Removing and installing rear axle shaft .
Mark position of propshaft in relation to propshaft flange.
Unscrew propshaft -2- from rear axle -1-.
Secure propshaft to body.
If fitted, remove spare wheel.
Vehicles with tachograph
Caution

Repair work which may affect the function of the tachograph


must always be carried out in certified workshops.

1. Final drive

17

Amarok 2011
Transfer box and final drive - Edition 05.2013
Tachograph
Continuation for all vehicles
Unscrew final drive cover from axle beam.
Vehicles with lockable differential
Disconnect connector of wiring harness from differential.
Unscrew securing bolt for wiring harness from bearing brack
et.
Continuation for all vehicles
Mark installation position of bearing brackets -1 and 2- and
remove -arrows-.
Caution

Always renew M8 securing bolts of expander - T50021- with


new bolts with property class 12.9 and washers before instal
lation.
Part number for M8 35 bolts: N10534803

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Specified torque: 44 Nm

Fit spreader - T50021- on rear axle.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

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Rep. gr.39 - Final drive - rear differential

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18

ht
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Part number for washers:

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WHT003198
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c
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s

Amarok 2011
Transfer box and final drive - Edition 05.2013
Mark installation side of tapered roller bearing outer races
-2- and shims -1-.
WARNING

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l purpos
hole
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Fit a bearing bracket again to prevent differential falling out


when expanding axle beam.

Wear safety goggles. Securing bolts of expander - T50021- are


highly stressed when axle is expanded.

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Tension spreader - T50021- until differential can be removed


from axle beam without significant effort.
Vehicles with lockable differential
Note

Handle differential with extreme caution and do not strike it

against any other object.

When driving connector out inwards, ensure that it does not

strike against actuator.

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Slacken spreader - T50021- and remove.

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by c
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Continuation for all vehicles

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Remove retainer for connector. Then, press connector in


wards out of axle housing and remove it together with differ
ential. Carefully pull connector out inwards.

thi
sd
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m
en

Risk of damage to axle differential lock Hall sender 1 - G460- .

Carry out visual inspection of tapered roller bearings on dif


ferential. Renew them if necessary page 32 .
Removing drive pinion
Caution

If the same drive pinion bearings are reinstalled, the friction


torque must be measured and recorded before dismantling
further. This is not necessary when installing new bearings.
Determining friction torque page 44 .
Remove locking device for nut -arrow-. If necessary, modify
counter-hold tool - 3145- page 44 .
Screw counter-hold tool - 3145- onto propshaft flange.
Loosen securing nut using 32 mm socket - T10209- .

1. Final drive

19

Amarok 2011
Transfer box and final drive - Edition 05.2013
Mount puller and remove propshaft flange.
A - Separating tool Kukko 17-2
B - Counter support Kukko 18-2
Carry out visual inspection of sealing sleeve. Renew it if nec
essary page 49 .
Use a plastic hammer for driving drive pinion out of housing.
If only the compression sleeve is to be renewed
Item 25 (page 12) , the last step that remains is to remove the
seal Item 21 (page 11) .
Drive out seal -1- using a chisel.
If the compression sleeve and the tapered roller bearings are to
be renewed, drive out outer races of tapered roller bearings.

Use drift - 3138- to drive out outer race of tapered roller bearing
(flange side) with seal.
Use drift - 3138- to drive out outer race of tapered roller bearing
(pinion side).
Carry out visual inspection of tapered roller bearings. Renew
them if necessary.

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Press tapered roller bearing Item 26 (page 12) off driveVpin
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ion page 30 .
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Installing

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Install in reverse order of removal, observing the following:

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If only the compression sleeve is to be removed, note


page 20 .

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

If the compression sleeve is to be renewed together with the ta


pered roller bearings, do the following:
Drive in outer races and determine shim for drive pinion
page 39 .
Then, fit determined shim onto drive pinion and press on ta
pered roller bearing page 30 .
Note

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Rep. gr.39 - Final drive - rear differential

do
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20

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Continuation for all cases:

r
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Remove any sealant residue from splines of flange before insert


ing the drive pinion.

Amarok 2011
Transfer box and final drive - Edition 05.2013
Insert drive pinion and support it using support device T10323- and press tool - VW 432- .
Fit new compression sleeve Item 25 (page 12) on drive pin
ion.

Drive in tapered roller bearing (flange side) using tube - VW


519- and press tool - VW 554- until axial play is approx 2 mm.

Drive in new seal flush using thrust piece - T50018Note


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Remove sealant residue thoroughly from
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Apply Loctite 565

b
ed
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o
h
to ainner
splines
ut
ss

ara
nte
e

of flange.

Caution

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Determine friction torque with crown wheel removed.


Determining friction torque
Bolt counter-hold tool - 3145- to propshaft flange.
Tighten flange nut with socket 32 mm - T10209- until the bear
ing has zero play.
Remove counter-hold tool - 3145- .

thi
sd
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hole
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, is n
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Install propshaft flange with new securing nut.

or
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1. Final drive

21

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Prote
cted
by

c
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C
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Amarok 2011
Transfer box and final drive - Edition 05.2013
To align tapered roller bearings, rotate propshaft flange 15
times clockwise and 15 times anticlockwise.

Measure friction torque on propshaft flange with a commer


cially available 32 mm socket , bearing preload gauge - VAS
6523- and cordless power driver 12 V/1.4 Ah - VAS 5825- .
Note

To avoid incorrect measurements, measure friction value at ap


prox. 50 rpm and turning at least 5 times.
AG. Volkswagen AG d
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is Nm
new, unoiled bearing: 2.25 Nm to 2.82
r
o
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s
used bearing: previously determined
value
+
0.1
s

Friction torque:

With
Nm to 0.5 Nm

Caution

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

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hole
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With

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If the determined friction torque is too low, tighten flange nut


further in small steps. Then, align propshaft flange again (ro
tate 15 times in clockwise and 15 times in anticlockwise direc
tion). After that, determine friction torque again. Repeat this
procedure until the friction torque is within the specified range.
It is very likely that this procedure has to be repeated several
times.
It is not permitted for friction torque to be attained by loosening
securing nut. Renew the compression sleeve if the permissible
friction torque has been exceeded Item 25 (page 12) . The
drive pinion must be removed for this purpose.

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Prote
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Rep. gr.39 - Final drive - rear differential

do
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22

Amarok 2011
Transfer box and final drive - Edition 05.2013
Secure flange nut by peening.
If the final drive gear set has been
pression sleeve and tapered roller

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dismantled completely
(com
ir se
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bearing), do
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or
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ac
a
ss

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

WARNING

es, in part or in w
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hole
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Continuation for all cases:

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Determine shims for crown wheel page 36 .

Always renew M8 securing bolts of expander - T50021- with


new bolts with property class 12.9 and washers before instal
lation.
Part number for M8 35 bolts: N10534803
Part number for washers: WHT001323

Install spreader - T50021- .

Wear safety goggles. Securing bolts of expander - T50021- are


highly stressed when axle is expanded.
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AG.

c
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.
C
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Tension spreader - T50021- until differential can be fitted into


axle beam without significant effort complete with tapered roll
er bearings and determined shims.

do
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en

WARNING

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Co
t.

Specified torque: 44 Nm

Prote
cted
by

Vehicles with lockable differential


Plug electrical connector into gearbox housing, taking due
note of following:

Wiring harness must not be kinked or pinched.

The connector stop faces downwards.

Continuation for all vehicles


Note
Do not interchange shims and tapered roller bearing outer

races for left and right sides.

Install chamfered side of shims towards axle tube.


When installing new shims, insert thinner shim (crown wheel

side) so as to achieve a backlash in all cases.

1. Final drive

23

Amarok 2011
Transfer box and final drive - Edition 05.2013
Install bearing brackets -1 and 2- in accordance with marked
installation position. Screw in bolts -arrows- finger-tight.
Slacken expander - T50021- and remove.
Tighten bearing brackets -1 and 2- to final torque.
Check backlash and contact pattern on newly adjusted final
drive gear sets page 27 .
Vehicles with lockable differential
Tighten bolt for wiring harness securing plate bracket and en
sure that wiring harness is not in contact with crown wheel
bolts.
Continuation for all vehicles
Clean sealing surfaces.

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Secure final drive cover with new gasket and new bolts. y Volks
b
ed
ris .
Install rear axle shafts Rep. gr. 42 ; Rear axle shafts
ho

Vehicles with lockable differential

un
le

Secure wiring harness bracket to rear axle.


Specified torques

1.1 Assembly overview - final drive, page 10


3.2 Assembly overview - Tirsan propshaft, page 54
Rear axle shafts, Assembly overview rear axle shafts Run
ning gear, axles, steering; Rep. gr. 42 ; Assembly overview rear axle shafts .
Component
Sender to gearbox housing

13 Nm

r
fo
ng

Dismantling and assembling differential

Convert two arm puller - T10040- with claw - T40001 /2- .

Special tools and workshop equipment required


-handelsblicher ZweiarmabzieherRemoving
Remove differential page 14 .

24

Rep. gr.39 - Final drive - rear differential

AG.

or

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Special tools and workshop equipment required

ht
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Co
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1.5

Specified torque

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
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um
en

Connect wiring harness to sender.

urposes, in part or in wh
ole,
cial p
is n
mer
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erm
or
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a
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Fill with gear oil page 67 .

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ss

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Install propshaft page 57 .

Amarok 2011
Transfer box and final drive - Edition 05.2013
Note
When pressing out pin, securing pin breaks between pin and

housing. Remove remains of securing pin, then, remove re


mains from housing as described below.

Fit a commercially available M6 nut between the two arm puller

- T10040- and stud -3- in order to prevent the tool from being
damaged.

Convert two arm puller - T10040- with claws - T40001 /2- .


Fit two arm puller - T10040- (or a -handelsblicher Zweiar
mabzieher- ) on housing -1- and press pin -2- in
-direction of arrow- out of housing.
WARNING

The securing pin is removed in three parts. The first part is


removed when driving out the pin, the remaining part must be
sheared off into two parts, the two parts must then be re
moved from the housing.

Note

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un
le

The securing pin breaks when removing pin -1- and a part re
mains in the pin -arrow a-.
When the pin is removed from the housing, the remaining part of
the securing pin -arrow b- must be removed in two parts from the
housing in the -direction of arrow- using a commercially available
driver. The lower part of the securing pin -arrow c- remains in the
housing hole.
Remove differential bevel gears and thrust washer from dif
ferential cage.
WARNING

The repair can be made 2 - 3 times.


When driving out the pin, a part of the securing pin remains in
the lower part of the differential housing.
r
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ng

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AG.

Prote
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c
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Note

ht
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Co
t.

When a new securing pin is inserted it presses the remains of


the old securing pin into the housing.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
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or
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p

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The hole is so deep that differential can be dismantled twice.

The guide ring will be destroyed during removal.


Renew guide ring if it is damaged.
If a damaged guide ring is used, the proper function of the lock

is no longer guaranteed.

1. Final drive

25

Amarok 2011
Transfer box and final drive - Edition 05.2013
Release guide ring -1- at locking lugs -arrows- and remove
selector fork from housing.
Remove guide ring and check it for damage.
Installing
Install in reverse order of removal, observing the following:
Use new guide ring.
Install thrust washers (qty. 4).
Note
Turn bevel gears by hand and check if they rotate freely before

installing the securing pin.

Drive new securing pin flush into differential housing.


Install differential page 14 .

3.2 Assembly overview -

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1.2 Assembly overview -

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1.1 Assembly overview -

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final drive, page 10
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Tirsan propshaft, page 54tho
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differential, page 13 s

1.6

Removing and installing crown wheel

26

Rep. gr.39 - Final drive - rear differential

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AG.

The bolts have a left-hand thread.

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Note

Prote
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by
c
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rig
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C
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Remove differential page 14 .

do
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um
en

Removing

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

Torque wrench - V.A.G 1332-

es, in part or in w
l purpos
hole
ercia
, is n
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com

Special tools and workshop equipment required

ht
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py
Co
t.

Specified torques

AG. Volkswagen AG d
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d
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Transfer box and final drive - eEdition
05.2013
ut
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hole
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Loosen bolts -2- of crown wheel -1-.

Using light blows, release crown wheel from drive. Then re


move bolts and remove crown wheel.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Installing

Install in reverse order of removal, observing the following:


Specified torques

1.1 Assembly overview - final drive, page 10


3.2 Assembly overview - Tirsan propshaft, page 54

1.7

Checking backlash and contact pattern

Special tools and workshop equipment required


Dial gauge - VAS 6079-

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by
c
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Universal dial gauge bracket - VW 387-

or
Without illustration:
Special tools and workshop equipment required
Dial gauge extension - T 50047/3Checking backlash:
Note
Only required for readjusting final drive gear set.
Align tip of dial gauge - VAS 6079- at a 90 angle with tooth

flank.

Adjust preload of dial gauge - VAS 6079- .

1. Final drive

27

Amarok 2011
Transfer box and final drive - Edition 05.2013
Install universal dial gauge bracket - VW 387with dial gauge
gen AG
AG. Volkswaon
en50047/3gT
- VAS 6079- and gauge extension
axledohous
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ing.
ua
by
d
se

Backlash can be changed using shims Item 7 (page 11) . If a


thinner shim is installed on one side, a shim that is thicker by cor
responding amount must be installed on other side so as to
maintain bearing preload of differential bearings.
Checking contact pattern:
Special tools and workshop equipment required

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AG.

Prote
cted
by

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.
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Spotting ink
Note

Only required for readjusting final drive gear set.


To check contact pattern, apply spotting ink to two teeth of
crown wheel offset by 180.
Mount retainer - T50022- and brake differential using setscrew
-arrow-.
Rotate differential at propshaft flange in both directions.
Check contact pattern.

28

Rep. gr.39 - Final drive - rear differential

ht
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py
Co
t.

r
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ng

Retaining tool - T50022-

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
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mer
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or
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Note

un
le

ri
Measure backlash; specification:
0.102 0.177 mm
tho

Amarok 2011
Transfer box and final drive - Edition 05.2013
Correct contact pattern
Note

Contact at tooth tip:


Note

Contact at tooth root:


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Note

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fo
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Reduce installation distance of crown wheel somewhat (crown


wheel closer to drive pinion) page 35 . This causes teeth to
engage somewhat more deeply whilst maintaining backlash.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
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In practice, it is not possible
to
achieve
such
an
ideal
contact
ua pat
b
ran
ed no point touches outer edge of tooth
ir sthat
tern. It is important
tee
o
h
t
or
surface.
u
ac
a
ss

Increase installation distance of crown wheel somewhat (remove


crown wheel from drive pinion) page 35 . This causes teeth
to engage somewhat less deeply whilst maintaining backlash.

1. Final drive

29

AG.

Prote
cted
by

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.8

Pulling tapered roller bearing for drive pinion off and pressing it on

Special tools and workshop


equipment required
Pressure plate - VW 401 Tube - VW 519 Thrust piece - 3118n AG. Volkswagen AG do
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Prote
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Procedure:
Remove drive pinion page 14 .
Then press tapered roller bearing -arrow- off drive pinion -1-.

30

Rep. gr.39 - Final drive - rear differential

do
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rrectness of i
t to the co
nform
spec
a
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wage
Separating tool Kukko 17-2
olks

Amarok 2011
Transfer box and final drive - Edition 05.2013
Press tapered roller bearing inner race off drive pinion.
A - Separating tool Kukko 17-2
AG. Volkswagen AG d
Determine shim for drive pinion before pressing on tapered
agen
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roller bearing page 39 .
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at
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his

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Press tapered roller bearing onto drive pinion.


Note

Ensure that drive pinion shim is correctly seated on back of drive


pinion head. Bearing must be fully in contact with shim. There
must be no gap between them.

do
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t.

1. Final drive

31

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by

AG.

Prote
cted
by

c
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C
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Amarok 2011
Transfer box and final drive - Edition 05.2013

1.9

Pulling tapered roller bearing for differential off and pressing it on

Special tools and workshop


equipment required
Tube - 2040 Thrust pad - VW 447 i Pressure plate - VW 401 Thrust piece - VW 473 Counter support Kukko
18-2
Separating tool Kukko 17-2

es, in part or in w
l purpos
hole
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or
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f
e
ng

Rep. gr.39 - Final drive - rear differential

AG.

32

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by

Prote
cted
by c
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C
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Open tapered roller bearing cage -arrow- with side cutters and
remove cage with rollers.

ht
rig
py
Co
t.

The tapered roller bearings are damaged beyond repair when


being removed and must be renewed.

thi
sd
o
cu
m
en

Note

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Dismantling

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h
ut
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a
c
s
s

Amarok 2011
Transfer box and final drive - Edition 05.2013
Pull off inner rings with thrust plate - VW 447 i- and tube 2040- .
1-

Counter support Kukko 18-2

2-

Separating tool Kukko 17-2

Assembling

Note
For pressing on 2nd tapered roller bearing, place thrust pad -

VW 447 i- under inner race of 1st tapered roller bearing.

n AG. Volkswagen AG do
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form
spec
atio
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n
thi
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en

urposes, in part or in wh
ole,
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Tapered roller bearings must make flush contact.

1. Final drive

33

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AG.

Prote
cted
by

c
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.
C
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Amarok 2011
Transfer box and final drive - Edition 05.2013

1.10

Overview of shims

1 - Compression sleeve
Renew
2 - Shim
For adjusting drive pin
ion
3 - Shim
On crown wheel side
For adjusting crown
wheel
Fitting position: cham
fered side faces axle
tube.

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ht
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Rep. gr.39 - Final drive - rear differential

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Co
t.

34

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en

urposes, in part or in wh
ole,
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is n
mer
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un
le

4 - Shim
Opposite side of crown
wheel.
For adjusting crown
wheel
Fitting position: cham
fered side faces axle
tube.

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.11

Adjustment overview
Note

Careful adjustment of the crown wheel and drive pinion is es

sential to ensure that the final drive gives long service and runs
silently. Therefore, the drive pinion and crown wheel are
matched during manufacture, and checked to ensure a good
mesh pattern and quiet running in both directions of rotation.
The position of quietest running is found by moving the drive
pinion axially while simultaneously lifting the crown wheel from
the zero-play mesh position by the amount necessary to main
tain the backlash within the specified tolerance.

The purpose of this adjustment is to re-establish the position

offering the quietest running as calculated on the test device G. Volkswagen


A
AG do
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during production.
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d b work and
The utmost care and cleanliness during all assembly
ise

r
measurements are essential to achieve a good
ho result.
ut
sa

Basic dimension to be set


2 - Crown wheel

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

1 - Drive pinion

es, in part or in w
l purpos
hole
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ng

and shims page 7 .

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s
Observe the general repair notes for tapered
roller bearings

a - Nominal default value = 112 mm


b - Middle of crown wheel
Adjustment overview
Note

Prote
cted
by

1)

Renew tapered roller bearing of drive pinion as well.

2)

Renew all tapered roller bearings of final drive gear set.

AG.

Compression sleeve3)
Differential cage

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Axle beam1)
Final drive gear set
(drive pinion and
crown wheel)1)
Tapered roller bear
ing2)

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Renewed component Adjusting drive pinion Adjusting crown


page 39
wheel
page 36

thi
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en

If repairs have been carried out on the final drive gear set it is only
necessary to adjust the drive pinion or crown wheel if components
have been renewed which have a direct effect on the adjustments
of the final drive. To prevent unnecessary adjustments, refer to
the following table:

3)

If the required friction torque was not achieved when the seal
for the propshaft flange was renewed, and therefore only the
compression sleeve was renewed, there is no need to readjust
the final drive gear set.

1. Final drive

35

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.12

Determining shims for crown wheel

Special tools and workshop equipment required

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

Note

To avoid mistakes when adjusting crown wheel, it is a good idea


to print out tables for calculating shim page 36 and enter
measured values.

Differential removed.

A - Measuring inside dimension of rear final drive housing:


Insert measuring piece - T50047/2- and measure gap using
feeler gauge .

B - Measuring differential axle dimension:


Place differential with tapered roller bearing outer races -1- on
level surface and measure total height.
C - Calculating shims for differential
Note
To achieve specified bearing preload, it is necessary to add a

constant value (pressure) to calculated basic dimension.

This range must be achieved using shims page 37 .


Bearing preload: 0.029 mm 0.048 mm
Calculation:
Tables for printing out, crown wheel adjustment

36

Rep. gr.39 - Final drive - rear differential

AG.

212.50 mm
0.70 mm
213.20 mm

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Prote
cted
by c
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Measuring piece dimension


+ Measured gap size
= Rear final drive housing inside dimension

ht
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Co
t.

Example:

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fo
ng

Calculate rear axle housing inside dimension by adding to


gether measured gap and measuring piece.

rrectne
s
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o
f
i
t to the co
n
form
spec
atio
h re
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wit
i
n
thi
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en

Feeler gauge

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Measuring piece - T50047/2-

Amarok 2011
Transfer box and final drive - Edition 05.2013
A - Measuring inside dimension of
rear final drive housing:
Measuring piece dimension
Measured gap size
Rear final drive housing inside di
mension

Measured:
mm
mm
mm

A=

B - Measuring differential axle di


mension:
Differential axle dimension

Example:

Measured:

212.50 mm
+0.70 mm
213.20 mm

Example:

B=

mm

201.00 mm

Note

The size of the individual shims ncorresponds


approximately
to half
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Measured:
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of

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hole
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, is n
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ot
com

C=

Note

Insert thinner shim on crown wheel side so as to achieve a

Shims page 37
1 mm shim thickness corresponds to approx. 1.4 mm back

Prote
cted
by

13
14
15
16
17
18
19
20
21
22

Thickness t (mm)
5.645
5.671
5.696
5.721
5.747
5.772
5.798
5.823
5.848
5.874

AG.

No.

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Crown wheel shims

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Co
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lash.

213.20 mm

mm
mm
mm
mm

+0.03 mm
-201.00 mm
12.23 mm
6.115 mm

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backlash in all cases, e.g. for a total shim thickness of 12.23


mm: crown wheel side, 6.102 mm and opposite side 6.128
mm.

mm

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

Rear final drive housing inside di


mension (A)
Value for bearing preload
Differential axle dimension (B)
Total thickness of shims
1/2 C =

Example:

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db
ise
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o
C - Calculating
thickness
thtotal
au
s
shims:
s

VW part number
WHT 006 443
WHT 006 443 A
WHT 006 443 B
WHT 006 443 C
WHT 006 443 D
WHT 006 443 E
WHT 006 443 F
WHT 006 443 G
WHT 006 443 H
WHT 006 443 J
1. Final drive

37

Amarok 2011
Transfer box and final drive - Edition 05.2013

5.899
5.925
5.950
5.975
6.001
6.026
6.052
6.077
6.102
6.128
6.153
6.179
6.204
6.229
6.255
6.280
6.306
6.331
6.356
6.382
6.407
6.433
6.458

WHT 006 443 K


WHT 006 443 L
WHT 006 443 M
WHT 006 443 N
WHT 006 443 P
WHT 006 443 Q
WHT 006 443 R
WHT 006 443 S
WHT 006 443 T
WHT 006 443 W
WHT 006 443 Y
WHT 006 443 Z
WHT 006 443 AA
olksw
agen AG
WHT
443
AB
AG. V
n006
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wage
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not
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o WHT 006 443 AC
V
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ris
WHT
006
443
AD
o
eo
h
t
u
ra
a
c
WHT 006 443 AE
ss
WHT 006 443 AF
WHT 006 443 AG
WHT 006 443 AH
WHT 006 443 AJ
WHT 006 443 AK
WHT 006 443 AL

If the shims for the crown wheel have been determined, do the
following:
Reinstall drive pinion and differential page 20 .
Check backlash and contact pattern page 27 .

agen
lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t
.
C
op
yi

Rep. gr.39 - Final drive - rear differential

ht
rig
py
Co
t.

38

do
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um
en

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n

23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

VW part number

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Thickness t (mm)

ility
ab
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an
pt
ce

No.

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.13

Determining shims for drive pinion

Special tools and workshop


equipment required
Dial gauge - VAS 6079 Setting tool - T 50047 Fitting tool - T50023 Thrust piece - T 50048-

r
fo
ng

Prote
cted
by

Drive pinion bearing shells must be pulled in.

AG.

Drive pinion removed.

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by

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gh
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.
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rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
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v
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un
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Feeler gauge

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tee
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or
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ss

ht
rig
py
Co
t.

Depth gauge

Pull in outer races of tapered roller bearings as far as stop


using fitting tool - T50023- as well as thrust piece - T50048/1and thrust piece - T50048/2- .

1. Final drive

39

Amarok 2011
Transfer box and final drive - Edition 05.2013

un
le

ility
ab
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an
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ce

AG. Volkswagen AG d
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ara
Installation position of fitting tool - T50023- in rear final drive
d
e
nte
s
i
r
housing.
o
eo
h
ut
ra
a
c
s
Measuring basic dimension (production tolerance)s on rear axle

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

housing

This means measuring piece is set to nominal basic dimen

sion.

Use dial gauge extension - T50047/4- .

40

Rep. gr.39 - Final drive - rear differential

AG.

Contact surfaces must be clean and free of burrs.

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by

Prote
cted
by c
o
p
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gh
t.
C
op
yi

Note

ht
rig
py
Co
t.

Adjust preload of dial gauge - VAS 6079- to 2 mm. Then, set


dial gauge - VAS 6079- to 0.

do
c
um
en

r
te o
iva
r
rp
fo
g
n

Secure dial gauge extension - T50047/4- on dial gauge - VAS


6079- , then insert it in measuring piece - T50047/2- and se
cure it using knurled screw. Secure tip of dial gauge - VAS
6079- on extension.

Amarok 2011
Transfer box and final drive - Edition 05.2013
Convert fitting tool - T50023- . To do this, turn thrust piece T50048/2- around and slide it onto fitting tool - T50023- .
Caution

To avoid incorrect measurements, the value must be deter


mined with tapered roller bearing installed.
Bolt measuring piece - T50047/1- to fitting tool - T50023- and
tighten it so that it barely has zero play.

ility
ab
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pt
ce

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
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o
nl
f
e
ng

n AG. Volkswagen AG do
es n
wage
s
k
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ot g
o
Insert the converted fitting tool - T50023- inbthe
y V rear final drive
ua
d
ran
housing. Insert tapered roller bearing with
ir se measuring piece tee
o
h
t
or
T50047/1- in rear final drive housingauand bolt the two parts
ac
together using the threaded rod. ss

Insert measuring piece - T50047/2- with dial gauge - VAS


6079- and dial gauge extension - T50047/4- in rear final drive
housing.
Caution

The dial gauge must be read anti-clockwise at the red figures.

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rig
py
Co
t.

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by

AG.

c
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p
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.
C
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yi

Determine reversal point on dial gauge - VAS 6079- by turning


it slightly back and forth in -direction of arrow-. Note the de
termined value.

thi
sd
o
cu
m
en

The thickness of the required shim is read directly on the dial


gauge - VAS 6079- .

Prote
cted
by

Shims page 41
Drive pinion shims

No.

Thickness t (mm)

VW part number

20
21
22
23
24
25

0.508
0.533
0.559
0.584
0.610
0.635

WHT 006 444


WHT 006 444 A
WHT 006 444 B
WHT 006 444 C
WHT 006 443 D
WHT 006 443 E
1. Final drive

41

Amarok 2011
Transfer box and final drive - Edition 05.2013
No.

Thickness t (mm)

VW part number

26
27
28
29
30
31
32
33
34
35
36
37
38
39

0.660
0.686
0.711
0.737
0.762
0.787
0.813
0.838
0.864
0.889
0.914
0.940
0.965
0.991

WHT 006 444 F


WHT 006 444 G
WHT 006 444 H
WHT 006 444 J
WHT 006 444 K
WHT 006 444 L
WHT 006 444 M
WHT 006 444 N
WHT 006 444 P
WHT 006 444 Q
WHT 006 444 R
WHT 006 444 S
WHT 006 444 T
WHT 006 444 W

n AG. Volkswagen AG do
es n
wage
s
k
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ot g
o
If the shim for the drive
do
y V pinion has been determined,
ua the fol
b
d
ran
lowing:
ir se
tee
o
h
t
or
au
Fit newssshim
onto drive pinion and press on tapered rollerac
urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

un
le

ility
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an
pt
ce

bearing page 30 .

agen
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Vo
by

AG.

Prote
cted
by

c
o
p
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gh
t
.
C
op
yi

Rep. gr.39 - Final drive - rear differential

ht
rig
py
Co
t.

42

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

r
fo
ng

Reinstall drive pinion and differential into rear final drive hous
ing page 20 .

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.14

Renewing propshaft flange seal

Special tools and workshop


equipment required
Counter-hold tool - 3145(modify holes)
Torque wrench - V.A.G
1332 Thrust piece - T50018 Socket 32 mm - T10209 Separating tool Kukko 17-2

AG. Volkswagen AG d
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not
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a
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Counter support Kukko


18-2

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
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an
pt
ce

ht
rig
py
Co
t.

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AG.

Bearing preload gauge - VAS 6523-

thi
sd
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cu
m
en

Special tools and workshop equipment required

e.g. cordless power driver 12 V/1.4 Ah - VAS 5825 Loctite 565

1. Final drive

43

Amarok 2011
Transfer box and final drive - Edition 05.2013
Caution

If the seal is renewed, the friction torque must be determined


before starting repair work page 44 .
If the friction torque has not been determined before removal,
the compression sleeve and the drive pinion bearings will have
to be renewed.
AG. Volkswagen AG d
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Counter-hold tool - 3145- is used
e
nte
is
r
o
ing nut for propshaft flange.
In
case
of
an
unmodified
tool,
drill
eo
h
ut
ra
a
out both holes in counter-hold
tool
3145to
dimension
-a=
c
s
s

Modifying counter-hold tool - 3145

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

A new counter-hold tool - 3145- with 10.5 mm holes will be


supplied.
Removing
Note

The brake drums must be removed, in order to prevent a poten


tially dragging brake from falsifying the measurement and causing
incorrect values.
Remove rear brake drums Brake systems; Rep. gr. 46 ;
Rear brakes; Resetting drum brake .
Unbolt propshaft from rear axle page 57 .
Prote
cted
by c
o
p
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C
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Check drive pinion bearing for axial play (no play permitted).
agen
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Measure friction torque on propshaft flange with a commer


cially available 32 mm socket , bearing preload gauge - VAS
6523- and a cordless power driver 12 V/1.4 Ah - VAS 5825- ,
for example.
.
AG.

Caution

To avoid incorrect measurements, measure friction torque


at approx. 50 rpm and turning at least 5 times.
Perform measurements carefully and accurately to pre
vent replacement of axle body.
Do not take any actions to alter friction torque before in
stalling seal on axle.
Note reading.

44

Rep. gr.39 - Final drive - rear differential

ht
rig
py
Co
t.

Secure propshaft to body.

do
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en

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hole
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Note

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10.5 mm .

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Transfer
box
and
final
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h
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Remove locking device for nut -arrows-.

Screw counter-hold tool - 3145- onto propshaft flange.

rrectness of i
t to the co
nform
spec
a
t
i
h re
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n in
wit
thi
s

es, in part or in w
l purpos
hole
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com

Loosen securing nut using 32 mm socket - T10209- .

Fit puller, as shown, and pull off propshaft flange.


A - Separating tool Kukko 17-2

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B - Counter support Kukko 18-2

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AG.

Prote
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by

Removing oil seal

Amarok 2011
- Edition 05.2013

c
o
p
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C
op
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Drive out seal -1- using a chisel.


Caution

Do not damage axle body when driving out seal.


Installing
Note
Remove any sealant residue from drive pinion and propshaft

flange.

If leaks are detected during repair work on the flange, always

renew the seal Item 21 (page 11) .

Check the contact surface of the propshaft flange seal for

traces of wear. Renew sealing sleeve if necessary


page 49 .

Before fitting the flange, seal the splines between the drive

pinion and the flange with Loctite 565 .

1. Final drive

45

Amarok 2011
Transfer box and final drive - Edition 05.2013
Drive in new seal flush using thrust piece - T50018 Install propshaft flange with new securing nut.

Component

Specified torque
30 Nm

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Nut

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Initial tightening torque

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 compression sleeve if
bearing is not yet without play after the nut has been tightened to
60 Nm.
Remove counter-hold tool - 3145- .

To align tapered roller bearings, rotate propshaft flange 15


times clockwise and 15 times anticlockwise.

Rep. gr.39 - Final drive - rear differential

AG.

46

agen
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Prote
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by c
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C
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Bolt counter-hold tool - 3145- to propshaft flange.

ht
rig
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Co
t.

Mark position of drive pinion in relation to one edge of securing


nut.

thi
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l purpos
hole
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AG. Volkswagen AG d
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Bolt counter-hold tool - 3145- to propshaft flange.
e
nte
is
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o
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h
ut - T10209- .
ra
Tighten securing nut using 32 mm socket
a
c
s
s

Amarok 2011
Transfer box and final drive - Edition 05.2013
Tighten securing nut by further 15 using 32 mm socket T10209- .
Remove counter-hold tool - 3145- .

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

To align tapered roller bearings, rotate propshaft flange 15


times clockwise and 15 times anticlockwise.
Bolt counter-hold tool - 3145- to propshaft flange.

Tighten securing nut 15 further using 32 mm socket T10209- .


ht
rig
py
Co
t.

Remove counterhold tool - 3145- .

thi
sd
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en

es, in part or in w
l purpos
hole
ercia
, is n
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1. Final drive

47

agen
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by

AG.

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Amarok 2011
Transfer box and final drive - Edition 05.2013
To align tapered roller bearings, rotate propshaft flange 15
times clockwise and 15 times anticlockwise.
Measure friction torque on propshaft flange with 32 mm socket
- T10209- , bearing preload gauge - VAS 6523- and e.g. cord
less power driver 12 V/1.4 Ah - VAS 5825- .
Note

To avoid incorrect measurements, measure friction value at ap


prox. 50 rpm and turning at least 5 times.
Friction torque:

With new, unoiled bearing: 2.25 Nm to 2.82 Nm

With used bearing: previously determined value + 0.1


Nm to 0.5 Nm
Caution

If the determined friction torque is too low, tighten nut in small


steps. Then, align propshaft flange again (rotate 15 times in
clockwise and 15 times in anticlockwise
direction). After that,
wagen AG
AG. Volksthis
n Repeat
e
determine friction torque again.
procedure
until the
g
does
a
w
not
olks specified range.
friction torque is within
Vthe
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se

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pe
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l purpos
hole
ercia
, is n
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ot
com

Secure securing nut by peening.


Install propshaft page 57 .
Install brake drums Brake systems; Rep. gr. 46 ; Rear
brakes; Resetting drum brake .
Operate brake pedal several times until brake shoes are in
contact with brake drum.
Check oil level and top up if necessary page 67 .
1.1 Assembly overview - final drive, page 10
3.2 Assembly overview - Tirsan propshaft, page 54

AG.

Prote
cted
by

Rep. gr.39 - Final drive - rear differential

agen
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c
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48

ht
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Co
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3.3 Assembly overview - Dana propshaft, page 55

do
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en

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Specified torques

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

It is not permitted for friction torque to be attained by loosening


securing nut. Renew the compression sleeve if the permissible
friction torque has been exceeded Item 25 (page 12) . The
drive pinion must be removed for this purpose.

ility
ab
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tee
ri this procedure has to be repeated several
It is very likely tthat
ho
or
u
ac
a
times.
ss

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.15

Repairing propshaft flange

Special tools and workshop


equipment required
Pressure plate - VW 402 Thrust piece - 40-105 Thrust pad - VW 511 Thrust piece - VW 442 Counter support Kukko
18-2

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Propshaft flange removed page 43 .

AG.

agen
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Pressing out

Prote
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by
c
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rig
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.
C
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Tube - 30 - 14-

ht
rig
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Co
t.

Special tools and workshop equipment required

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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en

urposes, in part or in wh
ole,
cial p
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un
le

Separating tool Kukko 17-2

1. Final drive

49

Amarok 2011
Transfer box and final drive - Edition 05.2013
Press out propshaft flange using thrust piece - 40-105- .
1-

Counter support Kukko 18-2

2-

Separating tool Kukko 17-2

Pressing on

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Press sealing sleeve onto dust cap using thrust plate - VW


511- .
Then reinstall propshaft flange page 43 .

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AG.

Prote
cted
by
c
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py
rig
ht
.
C
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yi

Rep. gr.39 - Final drive - rear differential

ht
rig
py
Co
t.

50

thi
sd
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cu
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en

es, in part or in w
l purpos
hole
ercia
, is n
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ot p
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erm
or
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t
a
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iv
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ng

Press dust cap onto propshaft flange using thrust piece - VW


442- and tube - 30 - 14- .

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AG. Volkswagen AG d
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Amarok 2011
Transfer box and final drive - Edition 05.2013

Differential lock

2.1 Functional check, page 51


2.2 Rear-axle differential lock components and their locations,
page 51

2.1

Functional check

A mechanical rear axle differential lock is now available as an


option in the Amarok with four-wheel drive.
When driving offroad, rear axle differential lock improves propul
sion on heavy ground, in particular when performing a hill start.
All functions that assist braking are deactivated when rear axle
differential lock is engaged, therefore rear axle differential lock is
lkswagen AG
. Voon
only allowed to be engaged when moving
off
heavy ground
gen AG
does or
swa
k
not
l
o
if carriageway is very soft.
gu
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b
ed

ris
In case of a selectable four-wheel
drive the rear differential lock
ho
ut
a
can be activated in offroad
range LOW.
s

ara
nte
e

Refer to Self-study programme No. 464 ; Power transmission


for more information about function.
Refer to Amarok owner's manual for more information and
notes on safety.

2.2

Rear-axle differential lock components


and their locations

Note

Electrical/electronic components and their locations for fourwheel drive page 94

do
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en

es, in part or in w
l purpos
hole
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, is n
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rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

The differential lock is switched on or off via the rear differential


lock switch - E121- . The differential lock control unit - J187checks via the CAN-Bus if the conditions to switch the rear axle
differential lock on have been fulfilled. If they have, then rear axle
differential lock is activated via axle differential lock Hall sender 1
- G460- and control solenoid - N5- .

or
ac
ility
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2. Differential lock

51

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l purpos
hole
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t
a
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nl
f
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Prote
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by

Rep. gr.39 - Final drive - rear differential

AG.

52

agen
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by

4 - Hall sender 1 for axle differ


ential lock - G460 With control solenoid N5 Location: on rear axle

do
c
um
en

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 .

c
o
p
yri
gh
t.
C
op
yi

2 - Diagnostic connection
Location: in driver foot
well

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Remove by removing centre


console General body re
pairs, interior; Rep. gr. 68 ;
Compartments, covers and
trims; Removing and installing
centre console .

ht
rig
py
Co
t.

1 - Differential lock control unit


- J187-

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Amarok 2011
Transfer box and final drive -

AG. Volkswagen AG d
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ise
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Edition s05.2013
sa

Amarok 2011
Transfer box and final drive - Edition 05.2013

Propshaft

3.1 Assembly overview - flexible coupling for propshaft, page


53
3.2 Assembly overview - Tirsan propshaft, page 54
3.3 Assembly overview - Dana propshaft, page 55
3.4 Removing and installing front propshaft, page 56
. Volkswage

n AG d
AG
3.5 Removing and installing
rear
agenpropshaft, page
o57
es n
ksw

un
le

propshaft intermediate bear

Assembly overview - flexible coupling for propshaft


rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
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ot
com

3.1

tee
or
ac

pe
rm
itte
d

ing, Tirsan propshaft, page 63

ot g
u

ara
propshaft intermediate bear
n

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db
3.6 Dismantling andiseassembling
r
ing, Dana propshaft,
ho page 60
ut
a
ss and assembling
3.7 Dismantling

1 - Bolt
Renew after removal
60 Nm +90
2 - Flexible coupling
Allocation Electronic
Parts Catalogue (ET
KA) .

r
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iva
r
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Co
t.

agen
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by

AG.

4 - Propshaft
Assembly overview Tirsan propshaft
page 54 .
Assembly overview Dana propshaft
page 55 .
Removing and installing
page 57

do
c
um
en

3 - Bolt
Renew after removal
For securing on gear
box.
90 Nm +90

Prote
cted
by

c
o
p
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gh
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C
op
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5 - Washer
6 - Nut
Renew after removal

3. Propshaft

53

Amarok 2011
Transfer box and final drive - Edition 05.2013

3.2

Assembly overview - Tirsan propshaft


Note

Volkswa
k
l
o
shaft must be raised and secured or supported.
yV
db
ise
r
Keep propshaft straight; store and transport
fully extended on
tho
au
ly.
s
s

gen AG
AG.
does
If propshaft is disconnected only from the rearswaxle,
agen the prop

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l purpos
hole
ercia
, is n
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ot p
om
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erm
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t
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itte
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or
nl
f
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not
gu
ara
nte
eo
ra
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rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

1 - Bolt
Renew after removal
50 Nm +90

2 - Rear propshaft
Removing and installing
page 57
3 - Dust cap
Renew after removal

4 - Propshaft intermediate
bearing
Dismantling and assem
bling propshaft inter
mediate bearing
page 63 .

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by

AG.

Prote
cted
by

c
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C
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6 - Bolt
Renew after removal
66 Nm

do
c
um
en

5 - Nut
Renew after removal
20 Nm +90

7 - Dust cap
Renew after removal
8 - Washer
9 - Rear propshaft
Removing and installing
page 57
10 - Bolt
Renew after removal
50 Nm +90
11 - Retaining ring
On front final drive
Renew after removal
12 - Front propshaft
All-wheel drive only
Coloured markings on pin of front final drive and front propshaft must be in alignment.
Always renew retaining rings Item 11 (page 54) and Item 13 (page 55) after propshaft has been
removed.
Removing and installing page 56

54

Rep. gr.39 - Final drive - rear differential

Amarok 2011
Transfer box and final drive - Edition 05.2013
13 - Retaining ring
Renew after removal

3.3

Assembly overview - Dana propshaft


Note

If propshaft is disconnected only from the rear axle, the prop

shaft must be raised and secured or supported.

Keep propshaft straight; store and transport fully extended on

ly.

1 - Bolt
Renew after removal
50 Nm +90

10 - Rear propshaft
Removing and installing
page 57
11 - Bolt
Renew after removal
50 Nm +90

thi
sd
o
cu
m
en

9 - Dust cap
Renew after removal

es, in part or in w
l purpos
hole
ercia
, is n
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ot p
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erm
or
e
t
a
itte
iv
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nl
f
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ng

8 - Seal
Renew after removal

AG.

7 - Propshaft intermediate
bearing
Dismantling and assem
bling propshaft inter
mediate bearing
page 60 .

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

6 - Nut
Renew after removal
20 Nm +90

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5 - Bearing bracket

Prote
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by
c
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rig
ht
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4 - Rubber ring

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3 - Dust cap
Renew after removal

AG. Volkswagen AG d
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ht
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Co
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2 - Rear propshaft
Removing and installing
page 57

12 - Retaining ring
On front final drive
Renew after removal
13 - Front propshaft
Four-wheel drive only
Coloured markings on pin of front final drive and front propshaft must be in alignment.

3. Propshaft

55

Amarok 2011
Transfer box and final drive - Edition 05.2013
Always renew retaining rings Item 12 (page 55) and Item 14 (page 56) after propshaft has been
removed.
Removing and installing page 56
14 - Retaining ring
Renew after removal

3.4

Removing and installing front propshaft

Special tools and workshop equipment required


Counter-hold tool - 3415-

Drive shaft grease Electronic Parts Catalogue (ETKA)


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.
Raise vehicle Maintenance ; Booklet 11 .
Remove engine/gearbox guard General body repairs, ex
terior; Rep. gr. 50 ; Engine/gearbox guard .
AG. Volkswagen AG d
Check if there are markings (paint spots) -A- on front propshaft
agen
oes
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not
l
o
and on front final drive.
V
gu
by

ara
nte
e

d
se

i
or
If these markings are not present, then markthposition
of prop
u paint.
a
shaft flange in relation to front final drive with
s

or
ac

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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o
nl
f
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ng

ility
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an
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ce

Prise front propshaft -1- off final drive using assembly lever.

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py
Co
t.

agen
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AG.

Prote
cted
by c
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p
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C
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Rep. gr.39 - Final drive - rear differential

thi
sd
o
cu
m
en

56

pe
rm
itte
d

Remove front propshaft.


Installing .

Amarok 2011
- Edition 05.2013

ility
ab
y li
an
pt
ce

un
le

Push front propshaft off


3415- .

AG. Volkswagen AG d
agen
oes and final drive
Transfer box
ksw
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rrectness of i
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a
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Install in reverse order of removal, observing the following:

Renew oil seals -1- if damaged.


Renew retaining rings -2-.

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Grease splines of shafts and oil seals -1- with drive shaft
grease Electronic Parts Catalogue (ETKA) .

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Markings -A- must be aligned with one another as far as pos


sible.
AG.

Position front propshaft on front final drive.


Caution

Wear protective gloves!

Then push front propshaft -1- onto shaft forcefully by hand until
it engages.
Pull on front propshaft to check propshaft has engaged cor
rectly.
Position front propshaft on transfer box.
Push front propshaft onto shaft until it engages.
Pull on front propshaft to check propshaft has engaged cor
rectly.
Install engine/gearbox guard General body repairs, exterior;
Rep. gr. 50 ; Engine/gearbox guard .
Specified torques
3.2 Assembly overview - Tirsan propshaft, page 54

3.5

Removing and installing rear propshaft

Special tools and workshop equipment required

3. Propshaft

57

Amarok 2011
Transfer box and final drive - Edition 05.2013
Torque wrench - V.A.G 1331-

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
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l purpos
hole
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Brake pedal actuator wheel drive)

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V.A.G 1869/2(vehicles with rearu
ac
a
ss

AG.

Prote
cted
by

the propshaft.

Remove and install propshaft with the help of a second me

chanic.

Before removing, mark positions of all parts relative to each

other. Reinstall in the same position otherwise imbalance will


be excessive, the mountings could be damaged causing rum
bling noises.

Keep propshaft straight; store and transport fully extended on

ly.

Do not let propshaft hang during removal; always support

it.

Always pull propshaft from or push it onto drive flange hori

zontally .

58

Rep. gr.39 - Final drive - rear differential

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If possible, use a twin pillar lifting platform when working on

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Note

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Counter-hold tool - T10172- (vehicles with four-wheel drive)

un
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Raise vehicle Maintenance ; Booklet 11 .


Unscrew securing bolts for propshaft on propshaft flanges, but
do not remove them yet.
Vehicles with four-wheel drive
Raise vehicle Maintenance ; Booklet 11 .
Unscrew securing bolts for propshaft on propshaft flanges, but
do not remove them yet. Brace using counter-hold tool T10172- .
Continuation for all vehicles
Caution

r
fo
ng

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.


Prote
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Note

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Install hexagon nuts for intermediate bearing -arrows-.

rrectne
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i
t to the co
n
form
spec
atio
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Fit brake pedal actuator - V.A.G 1869/2- .

Amarok 2011
and final drive - Edition 05.2013

ility
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AG. Volkswagen AG d
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Removing
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Vehicles with srear-wheel drive

A second mechanic is required for the further removal of the


propshaft.
Caution

To avoid damaging the protective boot in the intermediate


bearing, remove, store and install the propshaft with the joint
as straight as possible.
Unscrew propshaft at propshaft flanges and remove propshaft
with joint positioned as straight as possible.
Installing
Install in reverse order of removal, observing the following:
Install all parts which were marked in relation to each other in
their original positions.
Install propshaft with new bolts.
Installing intermediate bearing free of tension

All propshaft bolts are tightened.

Align intermediate bearing in its elongated holes so that nei


ther propshaft nor intermediate bearing is under tension.
Tighten new hexagon nuts.
Specified torques
3.2 Assembly overview - Tirsan propshaft, page 54

3. Propshaft

59

Amarok 2011
Transfer box and final drive - Edition 05.2013

3.6

Dismantling and assembling propshaft intermediate bearing, Dana prop


shaft

Special tools and workshop


equipment required
Thrust piece - 3118 Thrust pad - VW 510 Separating tool Kukko 17-2
Counter support Kukko
18-2

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Prote
cted
by

tion of the vehicle identification number.

H = Tirsan propshaft
A or 8 = Dana propshaft
Dismantling
Remove propshaft page 57 .

60

Rep. gr.39 - Final drive - rear differential

AG.

Sticker on propshaft or, if not legible anymore, the 11th posi

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Distinguishing features of propshafts:

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Note

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rrectness of i
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spec
a
t
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un
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Thrust pad - VW 447 H-

Amarok 2011
Transfer box and final drive - Edition 05.2013
Note
Mark position of propshaft before removing it.
The propshaft may also be installed reversed by 180.

n AG. Volkswagen AG do
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a
t
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Release dust cap.

Pull seal -1- and dust cap -2- off shaft.

do
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Clamp propshaft in a vice und pull shafts apart by hand.

3. Propshaft

61

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AG.

Prote
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.
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Amarok 2011
Transfer box and final drive - Edition 05.2013
Remove retaining ring.

agenaAknife
Cut rubber ring in marked area
-arrowwith
AG. Volksw
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removal and pull it off.Volksw
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Assembling

Install in reverse order of removal, observing the following:


Note

Use silicone lubricant - D 007 000 A2- to ease the installation

of the rubber ring.

Installation position of elastomer components in direction of

ht
rig
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Co
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Prote
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by
c
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rig
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travel.

Using thrust piece - 3118- and thrust plate - VW 510- drive


propshaft intermediate bearing onto propshaft as far as stop.

Rep. gr.39 - Final drive - rear differential

AG.

62

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Fit separating tool Kukko 17-2 and counter support Kukko 18-2
and press off propshaft using thrust plate - VW 447 H- .

do
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en

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l purpos
hole
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, is n
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au

Amarok 2011
Transfer box and final drive - Edition 05.2013
Then, install rubber ring by hand using silicone lubricant - D
007 000 A2- to ease installation.
Renew dust cap and seal. Grease splines.
Join parts of propshaft in area of splines and abruptly push
them together until the dust cap engages.
Specified torque

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Thrust piece - VW 454-

r
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Thrust pad - VW 447 H-

Prote
cted
by

Thrust piece - VW 433-

AG.

Counter support Kukko


18-2

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Separating tool Kukko 17-2

c
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C
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Special tools and workshop


equipment required

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en

Dismantling and assembling propshaft intermediate bearing, Tirsan prop


shaft

ht
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3.7

urposes, in part or in wh
ole,
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3.3 Assembly overview - Dana

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propshaft, page
b
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ise
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t
u
ra
a
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s
s

3. Propshaft

63

Amarok 2011
Transfer box and final drive - Edition 05.2013
Note
Distinguishing features of propshafts:
Sticker on propshaft or, if not legible anymore, the 11th posi

tion of the vehicle identification number.

H = Tirsan propshaft

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Dismantling

es, in part or in w
l purpos
hole
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ng

A or 8 = Dana propshaft

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Remove propshaft page 57 .

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Note

Mark position of propshaft before removing it.


Clamp propshaft in a vice.

Initially loosen bolt until the washer plate can be removed.

If the bolt is not long enough to press the propshaft parts apart

completely, the splines can be separated by light blows with a


-Kunststoffhammer- after the bolt has been loosened as far as
possible. Only strike against the joint section with inner
splines.

Pull propshaft apart.

64

Rep. gr.39 - Final drive - rear differential

AG.

edges of the spanner.

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by c
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Due to space restrictions it may be necessary to grind off the

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Co
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Note

thi
sd
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cu
m
en

Then, apply light pressure on the bolt head -arrow A- using a


commercially available assembly lever . Loosen bolt further
while doing so -arrow B-. This will cause the propshaft to be
pressed off.

Amarok 2011
Transfer box and final drive - Edition 05.2013
Note

ility
ab
y li
an
pt
ce

Fit separating tool Kukko 17-2 and counter support Kukko 18-2
with thrust piece - VW 433- to propshaft as shown in illustration
and press propshaft out of intermediate bearing.
Remove dust cap from propshaft.
Assembling

Install in reverse order of removal, observing the following:

The blue marking on the propshaft intermediate bearing must face


in direction of travel.

do
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en

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iva
r
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n

Note

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
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hole
ercia
, is n
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com

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AG. Volkswagen AG d
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Tighten separating tool
Kukko
17-2
only
slightly
(so
that
it uaran
e
is
tee
r
barely has zero play).
ho
or
ut
ac
a
ss
Otherwise the paintwork
of the propshaft may be damaged.

ht
rig
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Co
t.

Prote
cted
by c
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p
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C
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Drive new dust cap evenly onto propshaft as far as stop using
thrust piece - T10176- and a -Kunststoffhammer- .
agen
lksw
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by

AG.

Drive propshaft intermediate bearing onto propshaft as far as


stop using thrust plate - VW 447 H- , thrust piece - VW 454and a -Kunststoffhammer- .
Screw in bolt by several turns and join parts of propshaft (ob
serve marking). If necessary apply light blows with a plastic
hammer on the propshaft to join the parts.

3. Propshaft

65

Amarok 2011
Transfer box and final drive - Edition 05.2013
Note
If necessary, clamp the propshaft in a vice and strike it with a

plastic hammer at the marked positions -arrows-.

Do not strike against the universal joint.


Specified torque
3.2 Assembly overview - Tirsan propshaft, page 54

ht
rig
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AG.

Prote
cted
by
c
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rig
ht
.
C
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Rep. gr.39 - Final drive - rear differential

thi
sd
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en

66

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
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m
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erm
or
e
t
a
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f
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AG. Volkswagen AG d
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s

Amarok 2011
Transfer box and final drive - Edition 05.2013

Gear oil

4.1 Checking gear oil level in bevel box, page 67

4.1

Checking gear oil level in bevel box

Gear oil for the rear final drive is available as a part Electronic
parts catalogue ETKA .
Special tools and workshop equipment required
Torque wrench - V.A.G 1331-

Test precondition

Vehicle standing on level ground

Procedure
Raise vehicle Maintenance ; Booklet 11 .
Remove oil filler plug -arrow-.
The oil level is correct when the rear final drive is filled to the lower
. Volkswagen AG
edge of the filler hole; top up as required.
gen AG
d
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Screw in oil filler plug -arrow- and tighten.
db
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a
ss

un
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ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
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or
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1.1 Assembly overview - final drive, page 10

ht
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Co
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Specified torques

4. Gear oil

67

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AG.

Prote
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by

c
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.
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Amarok 2011
Transfer box and final drive - Edition 05.2013

39

Final drive - front differential

Final drive

1.1 Assembly overview - final drive, page 68


1.2 Removing and installing front final drive, page 68
1.3 Renewing bonded rubber bush on rear of final drive, page
73
AG. Volkswagen

AG do
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1.4 Renewing bonded rubber
page
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1.5 Renewing ubonded


rubber on left of final drive, page 77 ee or
tho
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Assembly overview - final drive

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1.1

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

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hole
ercia
, is n
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com

1 - Front final drive


Removing and installing
page 68 .
2 - Bolt
50 Nm +90
3 - Support bracket
4 - Hexagon collar bolt
90 Nm +90
5 - Retainer

7 - Hexagon collar bolt


50 Nm +90

AG.

Prote
cted
by

Removing and installing front final drive

Special tools and workshop equipment required


Torque wrench - V.A.G 1331 Torque wrench - V.A.G 1332-

68

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1.2

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8 - Hexagon collar nut

Rep. gr.39 - Final drive - front differential

do
c
um
en

r
te o
iva
r
rp
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n

6 - Hexagon collar bolt


90 Nm +90

Amarok 2011
Transfer box and final drive - Edition 05.2013
Engine and gearbox jack - V.A.G 1383 A Retainer - T10149Removing
Raise vehicle Maintenance ; Booklet 11 .
Remove front right wheel.
If fitted, remove engine/gearbox guard General body re
pairs, exterior; Rep. gr. 50 ; Engine/gearbox guard .
Remove front propshaft page 56 .
Remove right and left drive shafts from front final drive
Running gear, axles, steering; Rep. gr. 40 .
Remove front right transverse link Running gear, axles,
steering; Rep. gr. 40 .
Unclip breather hose
-2- at earth cable -1-.
Note

Illustration does not show engine to improve clarity.

Carefully pull breather hose -1- off front final drive -arrow-.
Right wheel suspension must be raised in order to remove front
n AG. Volkswagen AG do
securing bolt for front final drive.
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en

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Co
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iva
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rp
fo
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n

Turn right wheel hub until one of the wheel bolt holes is at the
top.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

un
le

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.

ility
ab
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an
pt
ce

olks
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db
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ris
WARNING
ho
ut
a
ss

1. Final drive

69

agen
lksw
Vo
by

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
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yi

Amarok 2011
Transfer box and final drive - Edition 05.2013
Attach support - T10149- to wheel hub using wheel bolt and
tighten.
n AG. Volkswagen AG do
Insert support - T10149- in engine and gearbox jack - V.A.G
es n
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s
k
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o
1383 A- .
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or
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ss

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e

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
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erm
or
e
t
a
itte
iv
r
du
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o
nl
f
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ng

WARNING

b
ed
ris
o
th
au

If the vehicle is not strapped down, there is a danger that the


vehicle will slip off the lifting platform!

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Unscrew and remove securing bolt for front final drive.


Lower wheel suspension again with engine and gearbox jack
- V.A.G 1383 A- .
Turn steering wheel to right lock.

Place engine and gearbox jack - V.A.G 1383 A- under front


final drive.
Remove support -A- and support bracket -B-.

Lower front final drive with engine and gearbox jack - V.A.G
1383 A- .
A second mechanic is required to remove front final drive.

Always renew securing bolts and hexagon nuts.


Check oil level in front final drive page 79 .
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- .

70

Rep. gr.39 - Final drive - front differential

AG.

Note

agen
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Vo
by

Installing

Prote
cted
by
c
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rig
ht
.
C
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Remove front final drive downwards.

ht
rig
py
Co
t.

First pull right drive shaft off front final drive, followed by left
drive shaft.

thi
sd
o
cu
m
en

Remove engine and gearbox jack - V.A.G 1383 A- .

Amarok 2011
Transfer box and final drive - Edition 05.2013
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 11 Raise
vehicle.
Turn right wheel hub until one of the wheel bolt holes is at the
top.
Attach support - T10149- to wheel hub using wheel bolt and
tighten.
Insert support - T10149- in engine and gearbox jack - V.A.G
1383 A- .
WARNING

If the vehicle is not strapped down, there is a danger that the


vehicle will slip off the lifting platform!

Raise wheel suspension using engine and gearbox jack V.A.G 1383 A- until securing bolt for front final drive is acces
sible above transverse link -arrow-.

rrectness of i
t to the co
nform
spec
at
i
h re
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wit
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his

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1. Final drive

71

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Amarok 2011
Transfer box and final drive - Edition 05.2013
Position new securing bolt for front final drive -1-, but do not
tighten yet.
Position new securing bolt for front final drive -4-, but do not
tighten yet.
Insert support -A-.
Position new
tighten yet.

Tighten securing bolt for front final drive -1-.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Lower wheel suspension again with engine and gearbox jack


- V.A.G 1383 A- .
Tighten securing bolt for front final drive -4-.
Tighten securing bolt for front final drive -5-.
First tighten securing bolt -2- and then securing bolt -3-.
Carefully push connection nipple of breather line -1- into front
final drive. When doing this the connecting nipple must be in
serted between the raised portions of the housing and be
horizontal -arrow-.

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Note

Illustration does not show engine to improve clarity.


Install front propshaft page 56 .
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 .
Specified torques
1.1 Assembly overview - final drive, page 68
3.2 Assembly overview - Tirsan propshaft, page 54

72

Rep. gr.39 - Final drive - front differential

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Clip breather hose -2- to earth cable -1-.

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First tighten securing bolt -7- and then securing bolt -6-.

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Position new

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securing
bolts -6- and -7-.
ss

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.3

Renewing bonded rubber bush on rear of final drive

Special tools and workshop


equipment required
Assembly tool - T10435 Assembly tool - T10254 Foot pump - VAS 6179 Hydraulic press - VAS
6178-

urposes, in part or in wh
ole,
cial p
is n
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erm
or
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Set foot pump - VAS 6179- to lowest setting.


Pulling out bonded rubber bush.
Note

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Pulling in

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Washer -A- from assembly tool - T10435-

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form
spec
atio
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wit
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thi
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Pulling out

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Tube - 30 - 14-

1. Final drive

73

Amarok 2011
Transfer box and final drive - Edition 05.2013
Position bonded rubber bush in installation position on front
final drive.
Note

Corners and small recesses of bonded rubber bush -arrows Amust be at right angles to final drive.
Mark installation position -arrow B- of bonded rubber bush.
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Pull-in depth for bonded rubber bush

AG.

Rep. gr.39 - Final drive - front differential

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74

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Dimension -a- = 47.4 mm

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form
spec
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urposes, in part or in wh
ole,
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s
Pull in bonded rubber bush until dimension
-a- page 74 is
reached.

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un
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Renewing bonded rubber bush on front of final drive

rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
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hole
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Special tools and workshop


equipment required

Amarok 2011
- Edition 05.2013

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1.4

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Transfer box and final
ntdrive
is
r
ee
o
h
or
ut
ac
a
s
s

Assembly tool - T10435 Assembly tool - T10254 Foot pump - VAS 6179 Hydraulic press - VAS
6178-

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Tube - 30 - 14-

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Prote
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by
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rig
ht
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C
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Pulling out
Set foot pump - VAS 6179- to lowest setting.
Pulling out bonded rubber bush.
Note

Washer -A- from assembly tool - T10435Pulling in

1. Final drive

75

un
le

rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
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es, in part or in w
l purpos
hole
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pe
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final drive.
Note

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AG. Volkswagen AG d
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Amarok 2011
gu
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Transfer box and final drive - Edition 05.2013
is
r
o
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h
ut
ra
a
c
s
s
Position bonded rubber bush in installation position
on front

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.

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Prote
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Rep. gr.39 - Final drive - front differential

ht
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76

do
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en

r
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Pull in bonded rubber bush until it is centred in front final drive


housing.

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.5

Renewing bonded rubber on left of final drive

Special tools and workshop


equipment required
Assembly tool - T10435 Assembly tool - T10254 Foot pump - VAS 6179-

r
fo
ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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um
en

urposes, in part or in wh
ole,
cial p
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Tube - 30 - 14-

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Hydraulic press - VAS


6178-

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Pulling out
Set foot pump - VAS 6179- to lowest setting.
Pulling out bonded rubber bush.
Note

Washer -A- from assembly tool - T10435Pulling in

1. Final drive

77

Amarok 2011
Transfer box and final drive - Edition 05.2013
Position bonded rubber bush in installation position on left of
final drive.
n AG. Volkswagen AG do
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b
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Small recesses of bonded rubber bush -arrows B- must be tat
right
o
h
or
u
ac
a
angles to final drive.
ss

Note

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le

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AG.

Prote
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Rep. gr.39 - Final drive - front differential

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78

ht
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ng

Pull in bonded rubber bush until it is centred in housing on left


of final drive.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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en

urposes, in part or in wh
ole,
cial p
is n
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a
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v
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Mark installation position -arrow A- of bonded rubber bush.

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Gear oil

2.1 Checking level of gear oil, page 79

2.1

Checking level of gear oil

Special tools and workshop equipment required


Torque wrench - V.A.G 1331-

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en

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Prote
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by
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Ring ratchet spanner, 13 mm AF - T10384-

rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his

Gear oil for the front final drive is available as a part Electronic
parts catalogue ETKA .

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Amarok 2011
final drive - Edition 05.2013

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AG.

Bit - T50039-

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.

2. Gear oil

79

Amarok 2011
Transfer box and final drive - Edition 05.2013
Test precondition

Front final drive in installation position

Procedure
Remove oil filler plug -arrow-.
The oil level is correct when the front final drive is filled to the lower
edge of the filler hole; top up as required.
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
edge of the filler hole; top up as required.
If necessary, replenish oil via breather hose, using a standard
funnel.
WARNING
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Exhaust system can berisehot.
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ut to cool down before replenishing oil.
ra
a
Allow exhaust system
c
s
s

Screw in oil filler plug -arrow- in combination with 13 mm ring


ratchet spanner - T10384- and bit - T50039- and tighten.

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Specified torque

Oil filler plug

35 Nm

AG.

Rep. gr.39 - Final drive - front differential

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80

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Co
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Component

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Specified torque

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l purpos
hole
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Danger of burning.

Amarok 2011
Transfer box and final drive - Edition 05.2013

Oil seals

3.1 Renewing left flange shaft oil seal, page 81


3.2 Renewing oil seal for right flange shaft, page 82
3.3 Renewing input shaft seal, page 84
3.4 Renewing dust cap for left flange shaft, page 87

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3.5 Renewing dust cap for right flange shaft, page
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Renewing left flangessshaft oil seal


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3.1

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Special tools and workshop equipment required

do
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t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
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Thrust piece - T10260-

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l purpos
hole
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com

Multipurpose tool - VW 771-

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3.6 Renewing needle bearing for left flange


ise shaft,
or

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ht
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Sealing grease Electronic Parts Catalogue (ETKA)


Procedure
Remove front final drive page 68 .
Pull out left flange shaft using multipurpose tool - VW 771- .

3. Oil seals

81

Amarok 2011
Transfer box and final drive - Edition 05.2013
Pull out oil seal for flange shaft using multipurpose tool - VW
771- .

Drive in new oil seal to stop using thrust piece - T10260- .


Fill space between dust lip and sealing lip half full with sealing
grease Electronic Parts Catalogue (ETKA) .
Before installing flange shaft, check dust cap for damage and
renew if necessary page 87 .
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t to the co
nf
o
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m
spec
atio
h re
n in
wit

Clamp flange shaft in vice using jaw protectors -B-.


Remove retaining ring -A- using pliers .
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 79 .
Install front final drive page 68 .

Renewing oil seal for right flange shaft

Special tools and workshop equipment required

AG.

Prote
cted
by

Rep. gr.39 - Final drive - front differential

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82

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Multipurpose tool - VW 771-

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en

3.2

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es, in part or in w
l purpos
hole
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com

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

Sealing grease Electronic Parts Catalogue (ETKA)


Procedure

Amarok 2011
drive - Edition 05.2013

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Thrust piece -

AG. Volkswagen AG d
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Transfer
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T10259- horis
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Remove front final drive page 68 .

do
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en

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Co
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Pull out right flange shaft using multipurpose tool - VW 771- .

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Prote
cted
by

c
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p
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C
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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- .


Fill space between dust lip and sealing lip half full with sealing
grease Electronic Parts Catalogue (ETKA) .

3. Oil seals

83

age and renew if necessary page 88 .

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
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Amarok 2011
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ran
Transfer box and final drive - Edition
ir se
tee
o
h
t
or
u
ac
a
ss dust cap -arrow- for dam
Before installing flange shaft, check

Clamp flange shaft in vice using jaw protectors -B-.


Remove retaining ring -A- using pliers .
Insert new retaining ring in groove in flange shaft, being careful
not to overstretch ring.
Check oil in front final drive page 79 .
c
o
p
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.
C
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Prote
cted
by

Special tools and workshop equipment required


Puller - T10055-

Thrust piece - T10430 Thrust piece - T10430/1 2 self-tapping screws with 4 mm diameter
Sealing grease Electronic Parts Catalogue (ETKA)
Procedure
Remove front propshaft page 56 .

84

Rep. gr.39 - Final drive - front differential

AG.

Renewing input shaft seal

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by

3.3

ht
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Co
t.

Install front final drive page 68 .

do
c
um
en

Drive in flange shaft using a plastic head hammer .

Amarok 2011
Transfer box and final drive - Edition 05.2013
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.

olksw
Screw in self-tapping gscrews
n AG diameter.
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d
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Pull out dustd cap
by using puller - T10055- .
e
ris

Screw in self-tapping screws with 4 mm diameter.


Note

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
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d
p

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ss

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ho to punch 2 holes in oil seal.


Use a drift
ut

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not
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Do not screw in sheet metal screw too far to avoid damaging


bearing behind it.
Pull out seal using puller - T10055- .

Mask off splines of stub shaft with adhesive tape.

ht
rig
py
Co
t.

r
fo
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On new seal, fill space between dust lip and sealing lip half full
with sealing grease Electronic Parts Catalogue (ETKA) .
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.
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Push new oil seal as far as oil seal seat on final drive.
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Prote
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by

Drive in seal to stop with thrust piece - T10430- , being careful


not to cant seal.

3. Oil seals

85

AG.

Amarok 2011
Transfer box and final drive - Edition 05.2013
Drive on new dust cap with thrust piece - T10430/1- .

Insert new oil seal -1- and new retaining ring -2-.
Check oil in front final drive page 79 .
Install front propshaft page 56

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Co
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Prote
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by
c
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rig
ht
.
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Rep. gr.39 - Final drive - front differential

do
c
um
en

86

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
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f
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AG. Volkswagen AG d
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Amarok 2011
Transfer box and final drive - Edition 05.2013

3.4

Renewing dust cap for left flange shaft

Special tools and workshop


equipment required
Press tool - VW 412 Thrust piece - VW 432 Support rails - VW 457 Pulling ring - 2003/3 Assembly tool - 3301-

AG. Volkswagen AG d
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Sealing grease Electron


ic Parts Catalogue (ETKA)

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Flange shaft removed, removing page 81

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-3- - Separating device Kukko 17-2

3. Oil seals

87

Amarok 2011
Transfer box and final drive - Edition 05.2013
Procedure
Press dust cap -B- off flange shaft.
A - Separating tool Kukko 17-2

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
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Assembly tool - 3301-

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Rep. gr.39 - Final drive - front differential

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88

Amarok 2011
Transfer box and final drive - Edition 05.2013
-3- - Separating device Kukko 17-2

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Flange shaftthremoved,
removing page 82
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Procedure s

A - Separating tool Kukko 17-2

Drive on new dust cap for flange shaft -A- using thrust piece 3456- and sleeve - 3301/3- .

Position sleeve - 3301/3- with notch facing dust cap -A-.

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ole,
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Press dust cap -B- off flange shaft.

3. Oil seals

89

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AG.

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Amarok 2011
Transfer box and final drive - Edition 05.2013

3.6

Renewing needle bearing for left flange shaft

Special tools and workshop


equipment required
Press tool - 30 - 505 Press tool - 30 - 506 B Internal puller Kukko 21-6
-1-

urposes, in part or in wh
ole,
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Remove front final drive page 68 .

Remove left flange shaft and oil seal page 81 .

Rep. gr.39 - Final drive - front differential

AG.

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90

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B - Counter support Kukko 22-2

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A - Internal puller Kukko 21-6

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Pull out left flange shaft needle bearing.

rrectne
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form
spec
atio
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Procedure

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Counter support Kukko


22-2 -4-

Amarok 2011
Transfer box and final drive - Edition 05.2013
Drive in needle bearing for left flange shaft -A- to stop.
Install left flange shaft and oil seal page 81 .
Check oil in front final drive page 79 .

AG. Volkswagen AG d
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Install front final drive page 68 .

3. Oil seals

91

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AG.

Prote
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c
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Amarok 2011
Transfer box and final drive - Edition 05.2013

39

Final drive - differential

Transfer box

1.1 Assembly overview - transfer box, page 92


1.2 Components and their locations, page 94
1.3 Removing and installing transfer box, page 95
1.4 Checking gear oil level, page 97
1.5 Removing and installing transfer box control unit J646 ,
page 99

5 - Dowel sleeve
Qty. 2
For centring gearbox/
transfer box
6 - Transfer box inter-axle lockup switch - F438 27 Nm
7 - Seal
Renew if damaged
8 - Retaining ring
Renew after removal
On input shaft for front
propshaft
9 - Seal
On output shaft for front
propshaft
Renew if damaged

Rep. gr.39 - Final drive - differential

thi
sd
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cu
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4 - Seal
Renew after removal
Insert in groove in input
shaft page 94

AG.

3 - Seal
For input shaft
Removing and installing
page 102 .

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2 - Breather pipe
Removing page 94
Driving in page 94

rrectness of i
t to the co
nf
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spec
atio
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n in
wit

1 - Transfer box
Removing and installing
page 95 .

92

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hole
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Assembly overview - transfer box

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1.1

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page 100

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1.6 Removing and installing transfer box Hall sender G759
by ,
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page 99
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1.7 Removing and installing transfer box control motor
V455
,
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spec
atio
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wit

13 - Seal
Renew if damaged
Must lie in peripheral groove of transfer box control motor - V45514 - Oil drain plug
Renew after removal
27 Nm
15 - Oil filler plug
Renew after removal
27 Nm

AG.

18 - Bolt
7 Nm

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17 - Transfer box Hall sender - G759 Removing and installing page 99 .

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16 - Seal
Cannot be obtained individually

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11 - Transfer box control motor - V455 Removing and installing page 100 .
12 - Bolt
12 Nm

Amarok 2011
Edition 05.2013

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10 - Seal
For output shaft for front
2-piece

Transfer
and final drive olkswagenbox
AG. V
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19 - Nut
Renew after removal
Unscrewing page 106
Screwing on page 107
150 Nm
20 - Seal
Renew after removal
Coat with gear oil when installing
21 - Propshaft flange
For rear propshaft.
Removing and installing page 105 .
22 - Seal
For propshaft flange
Renew with propshaft flange page 105

1. Transfer box

93

Amarok 2011
Transfer box and final drive - Edition 05.2013
n AG. Volkswagen AG do
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wa-1Inserting oil seal into groove in input shaft
olks

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Removing breather pipe

Use pliers to move breather pipe -1- in directions of both ar


rows and pull out.

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Prote
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Before driving in breather pipe -1-, coat it with Loctite locking


fluid Electronic Parts Catalogue (ETKA) .
AG.

Drive breather pipe to stop with thrust piece - T10203- .

1.2

Components and their locations


Note

Electrical and electronic components of rear-axle differential

lock page 51

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.

94

Rep. gr.39 - Final drive - differential

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Driving in breather pipe

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1 - Transfer box
J646 Location: under dash
panel
Removing and installing
page 99 .

Amarok 2011
drive - Edition 05.2013

2 - Diagnostic connection
Location: in driver foot
well

do
c
um
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3 - Running gear programme


switch - E631 Deactivate for fourwheel drive
Remove by removing
selector mechanism
cover General body
repairs, interior; Rep.
gr. 68 ; Compartments,
covers and trims; Re
moving and installing
centre console

4 - Transfer box operating unit


With reduction gearing
warning lamp in transfer
box operating unit K182 With inter-axle lock-up
warning lamp in transfer
box operating unit K183 With rear axle differen
tial 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; Removing and
installing centre console
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5 - Running gear programme switch - E631 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
6 - Transfer box control motor - V455 Location: on transfer box
Removing and installing page 100 .
7 - Transfer box inter-axle lock-up switch - F438 Location: on transfer box
Removing and installing page 92 .
8 - Transfer box Hall sender - G759 Location: on transfer box
Removing and installing page 99 .

1.3

Removing and installing transfer box

Special tools and workshop equipment required

1. Transfer box

95

Amarok 2011
Transfer box and final drive - Edition 05.2013
Torque wrench - V.A.G 1331-

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Engine and gearbox jack - V.A.G 1383 A-

Drive shaft grease Electronic Parts Catalogue (ETKA)


Removing

Remove rear propshaft page 57 .


Remove front propshaft page 56 .

AG.

Prote
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by

Rep. gr.39 - Final drive - differential

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c
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96

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Pull breather line -arrow- off transfer box.

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Detach connector -arrows- and unclip wiring harness from


transfer box.

Amarok 2011
Transfer box and final drive - Edition 05.2013
Position engine and gearbox jack - V.A.G 1383 A- under trans
fer box.
Unscrew and remove transfer box/gearbox connecting bolts.
Press transfer box off gearbox.
Lower transfer box with engine and gearbox jack - V.A.G 1383
A- .
Installing
Install in reverse order of removal, observing the following:
Check whether dowel sleeves for aligning gearbox and trans
fer box are fitted in gearbox; installgifennecessary.
AG. Volkswagen AG d

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

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 56 .
Install rear propshaft page 57 .
Check oil level in transfer box page 97 .
Prote
cted
by c
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C
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1.1 Assembly overview - transfer box, page 92


3.2 Assembly overview - Tirsan propshaft, page 54

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Component

Specified torque

Transfer box to gearbox

45 Nm

AG.

1.4

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Specified torques

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Grease transfer box input shaft splines and gearbox output


shaft splines with drive shaft grease Electronic Parts Cata
logue (ETKA) .

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Always renew oil seal torisseal
transfer box and gearbox -1- and rante
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lubricate lightly.
t
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c
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Checking gear oil level

Gearbox oil specification Electronic parts catalogue ETKA


Special tools and workshop equipment required

1. Transfer box

97

Amarok 2011
Transfer box and final drive - Edition 05.2013

AG. Volkswagen AG d
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Torque wrench - V.A.G 1331-

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Make a tool to check oil level.


Dimension -a- = 37 mm
Dimension -b- = 60 mm
Procedure

Raise vehicle Maintenance ; Booklet 11 .


Remove oil filler plug -1-.

Pull out tool and check oil level on tool. Top up oil if necessary.
The oil level must be within a range of 32 to 37 mm below lower
edge of filler hole.
Prote
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by c
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AG.

Remove oil filler plug -1-.

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When filling with oil, note the following:


Fill 1.25 l of gear oil.
Tighten new oil filler plug.
Specified torques

1.1 Assembly overview - transfer box, page 92

98

Rep. gr.39 - Final drive - differential

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Tighten new oil filler plug.

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Insert locally manufactured tool into filler hole downwards as


far as possible.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

Oil level is below oil filler hole.

Amarok 2011
Transfer box and final drive - Edition 05.2013

1.5

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, observing the following:
Transfer box control unit - J646- must engage in bracket.

1.6

Removing and installing transfer box


Hall sender - G759-

Special tools and workshop equipment required


Torque wrench - V.A.G 1331-

Removing

es, in part or in w
l purpos
hole
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, is n
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Pull off connector -1-.

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Place drip tray under transfer box.

Installing

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Remove bolts -arrows- and pull transfer box Hall sender G759- off transfer box.
Install in reverse order of removal, observing the following:

do
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1. Transfer box

99

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Prote
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by c
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C
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Amarok 2011
Transfer box and final drive - Edition 05.2013
Renew oil seal -1- if damaged.lkswagen

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d

The drive for the transfer box Hall sender - G759- -arrow Bes, in part or in w
l purpos
hole
ercia
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rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

and the mounting for the transfer box -arrow A- are offset. The
drive only fits in one position in the mounting for the transfer
box.

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When positioning transfer box Hall sender - G759- , insert

centring pin into hole in transfer box -A-.


Caution

It must be possible to insert transfer box Hall sender G759- without exerting great pressure, if necessary check
whether driver -arrow B- has been turned through 180 to
mounting -arrow A-.

Tighten bolts of transfer box Hall sender - G759- -arrows-.


c
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Check oil in transfer box page 97 .


Prote
cted
by

1.1 Assembly overview - transfer box, page 92

Removing and installing transfer box


control motor - V455-

Special tools and workshop equipment required


Torque wrench - V.A.G 1331-

Removing
Raise vehicle Maintenance ; Booklet 11 .

100

AG.

1.7

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Specified torques

Rep. gr.39 - Final drive - differential

ht
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Co
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Push on connector -1-.

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en

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Insert transfer box Hall sender - G759- .

Amarok 2011
Transfer box and final drive - Edition 05.2013
Pull connector -1- off transfer box control motor - V455- .
Place drip tray under transfer box.
Remove bolts -2- and pull transfer box Hall sender - V455- off
transfer box.
Installing
Install in reverse order of removal, observing the following:

Renew oil seal -1- if damaged.

es, in part or in w
l purpos
hole
ercia
, is n
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ot p
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AG. Volkswagen AG d
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Tighten bolts -2- for transfer box control motor - V455- .

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Push on connector -1-.

Check oil in transfer box page 97 .


Specified torques

1.1 Assembly overview - transfer box, page 92

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ht
rig
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Co
t.

1. Transfer box

101

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AG.

Prote
cted
by

c
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Amarok 2011
Transfer box and final drive - Edition 05.2013

Oil seals

2.1 Renewing input shaft seal, page 102


2.2 Renewing output shaft seal, page 103
2.3 Renewing propshaft flange seal, page 105

2.1

Renewing input shaft seal

Special tools and workshop equipment required


Puller - T10055-

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l purpos
hole
ercia
, is n
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ot p
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Thrust piece - T10184-

Sealing grease Electronic Parts Catalogue (ETKA)

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Remove transfer box page 95 .

AG.

Rep. gr.39 - Final drive - differential

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102

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Co
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Removing

do
c
um
en

Sheet metal screw, approx. 4 mm in diameter

Amarok 2011
Transfer box and final drive - Edition 05.2013
To pull out seal, screw sheet metal screw of about 4 mm di
ameter -arrow- into seal.
Caution

Pull out seal using puller - T10055- .


Installing

Install in reverse order of removal, observing the following:


Fill space between dust lip and sealing lip half full with sealing
grease Electronic Parts Catalogue (ETKA) .
Drive in new seal to stop with thrust piece - T10184- , being
careful not to cant seal.
Install transfer box page 95 .

Check oil in transfer box page 97 .

2.2

Renewing output shaft seal

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Prote
cted
by

Thrust piece - T10449-

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Special tools and workshop equipment required

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Do not screw in sheet metal screw too far to


bearing behind it.

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Hub grease cap puller - VW 637/2-

2. Oil seals

103

Amarok 2011
Transfer box and final drive - Edition 05.2013
AG. Volkswagen AG d
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extractor lever - VW 681-

Sealing grease Electronic Parts Catalogue (ETKA)


Removing

Remove front propshaft page 56 .

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Prote
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by
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Pull seal out with oil seal extractor lever - VW 681- .


Installing
Install in reverse order of removal, observing the following:
Fill space between dust lip and sealing lip half full with sealing
grease Electronic Parts Catalogue (ETKA) .
Position new seal on transfer box.
Push inner part of seal onto output shaft as far as possible.
Drive in new seal to stop with thrust piece - T10449- , being
careful not to cant seal.
Install front propshaft page 56 .
Check oil in transfer box page 97 .

104

Rep. gr.39 - Final drive - differential

ht
rig
py
Co
t.

Pull out seal using hub grease cap puller - VW 637/2- .

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um
en

r
te o
iva
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n

Lift inner part of seal in three places using a screwdriver, offset


120

Amarok 2011
Transfer box and final drive - Edition 05.2013

2.3

Renewing propshaft flange seal

Special tools and workshop


equipment required
Counter-hold tool - 3145 Thrust piece - VW 442 Removal and installing tool
- VW 459/2 Puller hooks - T20143/2 Torque wrench - V.A.G
1332 Sealing grease Electron
ic Parts Catalogue (ETKA)
Bolts M10 x 25 (Qty. 2)

If leaks are detected during repair work on the flange, always

renew the seal Item 23 (page 12) and the sealing sleeve
Item 20 (page 11) .

Always renew oil seal and propshaft flange together.


Removing

Remove rear propshaft page 57 .

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Note

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sd
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AG. Volkswagen AG d
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2. Oil seals

105

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AG.

Prote
cted
by c
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t.
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Amarok 2011
Transfer box and final drive - Edition 05.2013
Unscrew nut for propshaft flange. Screw counter-hold tool 3145- onto propshaft flange using two M10 x 25 bolts
-arrows- in order to counter-hold tool.
Place drip tray under transfer box.

es, in part or in w
l purpos
hole
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If necessary, pull off propshaft flange using puller Kukko 18-1


-A- and adapter - VW 295 A- .

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Pull out seal using puller hooks - T20143/2- .


Installing

Lightly oil outer circumference of new oil seal.

Prote
cted
by

106

Rep. gr.39 - Final drive - differential

AG.

Insert new propshaft flange.

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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.

ht
rig
py
Co
t.

Fill space between dust lip and sealing lip half full with sealing
grease Electronic Parts Catalogue (ETKA) .

do
c
um
en

Install in reverse order of removal, observing the following:

Amarok 2011
Transfer box and final drive - Edition 05.2013

Install new nut for propshaft flange and tighten. Screw counterhold tool - 3145- onto propshaft flange using two M10 x 25
bolts -arrows- in order to counter-hold tool.
Install rear propshaft page 57 .
Check oil in transfer box page 97 .
Specified torques

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Co
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fo
ng

1.1 Assembly overview - transfer box, page 92

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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en

urposes, in part or in wh
ole,
cial p
is n
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itte
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AG. Volkswagen AG d
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un
le

Moisten new oil seal -1- with gear oil and insert.

2. Oil seals

107

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lksw
Vo
by

AG.

Prote
cted
by

c
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C
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