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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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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.
Amarok 2011 2011 ➤ Transfer box and final drive - Edition 09.2010
2.1 2.1 2.2 2.2
Loca Locati tion on on tran transf sfer er box box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Iden Identi tifi fica cati tion on code code,, ass assem embl bly y all alloc ocat atio ion, n, capa capaci citi ties es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 3.1 3.2 3.2
n AG Loca Locati tion on on fron frontt fin final al driv drive e . . . . . . . . s w . a. g. e. n.AG . .. V. . . . a. g.e .n . . .d o .e .s . . . . . . . . . . . . . . . . . . . . . k n l o V Iden Identi tifi fica cati tion on code code,, ass assem embl bly y all alloc ocat atio ion, n, capa capaci citi ties es . . . . . . . . . . .o t .g .u a . . . . . . . . . . . . . . . . . y d b
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37 38
3.1 3.1 3.2 3.2 3.3 3.3 3.4 3.4 3.5 3.5
Rene Renewi wing ng oil oil sea seall for for left left flan flange ge shaf shaftt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rene Renewi wing ng seal seal for for rig right ht flan flange ge shaf shaftt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rene Renewi wing ng inpu inputt sha shaft ft seal seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rene Renewi wing ng dust dust cap cap for for left left flan flange ge shaf shaftt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rene Renewi wing ng dust dust cap cap for for rig right ht flan flange ge shaf shaftt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 42 44 47 48
Contents
i
Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010 5.1 5.2 5.3
Pulling bonded rubber bush on rear housing out and in . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulling bonded rubber bush out of and into front of housing . . . . . . . . . . . . . . . . . . . . . . . . Pulling bonded rubber bush on left of housing out and in . . . . . . . . . . . . . . . . . . . . . . . . . . . Volksw age n AG
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1.1 1.2 1.3
52 53 54
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Assembly overview - propshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . u d Removing and installing front propshaft . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. e t t i Removing and installing rear propshaft m . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . r
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Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
❑ Removing and installing G. Volksw age n AG ⇒ page 37 g e n A d oe w a l k s o
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t ❑ n o With reduction gearing s ❑ e Changing between on‐ l o road range „HIGH“ and h w offroad range „LOW“ is n performed using run‐ o ning gear programme a p switch -E631 i , ⇒ page 10 e ❑ Removing and installing o p ⇒ page 12 u
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1. Overview - four-wheel drive power train
1
Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
Transfer box 07C is allocated to manual gearbox 06C. A reduction gearing is integrated into the transfer box. Codes ⇒ page 2 . n AG a g e
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I I o c r o Identifica‐ e t acode tion v i
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Transfer box Allocation Capacity The following data can be found in the ⇒ Electronic parts cata‐ logue „ETKA“ . ♦ Allocation to corresponding vehicle by identification code of manual gearbox ♦ Specification of gear oil
2
Rep. gr.00 - Technical data
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0C7 Model
Amarok 2011 ►
Engine
2.0 l - 120 kW 1.25 l
Amarok 2011 2011 ➤ Transfer box and final drive - Edition 09.2010
Front final drive 0C1 is allocated to manual gearbox 06C. Codes ⇒ page 3 . 3 .
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Capacity
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Model
Amarok 2011 2011 ►
Engine
2.0 l - 120 kW 0.8 l
The following data can be found in the ⇒ Electronic parts cata‐ logue „ETKA“ . ♦ Allocatio Allocation n to correspon corresponding ding vehicl vehicle e by engine engine code ♦ Speci Specific ficati ation on of gea gearr oil oil
3. Identifying front final drive
3
Amarok 2011 2011 ➤ Transfer box and final drive - Edition 09.2010
Rear final drive
0CC
Allocation Ratio
Model
Amarok 2011 2011 ►
Amarok 2011 2011 ►
Engine
2.0 l - 120 kW
2.0 l - 120 kW
i = 4.1
i = 4.1
Final drive 1.5 l1)
Capacity 1) 2.1
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– Only rolling rolling roads with brakes brake m s ion all 4 rollers may be used for r performance tests. e p
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5. Four-wheel drive - notes on performance test
5
Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
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. . Volksw age n AG
G e n A
d oe a g s n s w A number of generally applicable o l kinstructions for the various re‐ o V pair procedures which were dpreviously repeated at numerous t g u a r a b y e n t i s r places in the workshop manual are summarised here. They apply e o e h t o u r to this workshop manual. a a c s
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o renew retaining rings for front propshaft on transfer ♦ Always box and a front final drive. p
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♦ When ,installing mounting brackets or waxed components, clean e the contact surfaces. Contact surfaces must be free of o p grease. wax and i
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♦ Allocate abolts and other components using ⇒ Electronic parts c r (ETKA) . catalogue e l
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♦ When o c r ⇒ page 14 . o
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ffront final drive, top up with gear oil ♦ When changing g n i y ⇒ page 56 . p o
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When changing rear axle, top up with gear oil ⇒ page 35 . Capacity of rear final drive ⇒ page 4 .
♦ Renew seals. ♦ Radial oil seals.
Lightly oil outer diameter and half-fill space between sealing lips -arrow- with grease -G 052 128 A1- .
♦ Check oil level in transfer box ⇒ page 14 . ♦ Checking oil level in front final drive ⇒ page 56 . ♦ Checking oil level in rear final drive ⇒ page 3 .
♦ Renew retaining rings. ♦ Do not overstretch retaining rings. ♦ Retaining rings must locate properly in grooves.
6
Rep. gr.00 - Technical data
r y i g
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Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
♦ Loosen and tighten bolts and nuts for covers and housings diagonally. ♦ Torque settings are specified for unoiled bolts and nuts. ♦ Always renew self-locking bolts and nuts. ♦ Ensure with threaded connections that contact surfaces as well as nuts and bolts are rewaxed only after assembly, if nec‐ essary. ♦ Use a thread chaser to clear residual locking fluid from all threaded holes into which self-locking bolts are to be screwed. Otherwise there is a danger of bolts shearing when subse‐ quently being removed.
♦ Install needle bearings with lettered side (thicker metal) to‐ wards fitting tool.
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6. General repair notes
7
Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
♦ Vehicle diagnosis, testing and information system -VAS 5051B- or successor. . Volksw age n AG
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Rep. gr.34 - Controls, housing
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Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010 – With ignition switched off, connect vehicle diagnosis, testing and information system -VAS 5051B- to diagnostic connec‐ tion. Location: Driver footwell. – Switch on tester. The tester is operational when it displays a picture of a car. – Switch on ignition.
– Touch Gui ded f aul t f i ndi ng button on screen. – Select in succession: ♦ Brand ♦ Model ♦ Model year ♦ Version ♦ Engine code – Confirm input data.
Wait until tester has read all control units in vehicle. – Press Got o button and select Sel ect f unct i on/ component function. G. Volksw age n AG g e n A Now follow
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1. Connecting vehicle diagnosis, testing and information system VAS 5051B or vehicle diagnosis and service information system VAS 5052 A and selecting functions
9
Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
♦ Electrical and electronic components of rear axle differential lock ⇒ page 29 ♦ Refer to ⇒ Self-study programme No. 464 ; Power transmis‐ sion for more information about function. ♦ Refer to ⇒ Amarok owner's manual for more information and notes on safety.
❑ Location: under dash panel ❑ Removing and installing ⇒ page 11 ❑ Location: in driver foot‐ well G e n A a g
❑ 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
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❑ 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
10
Rep. gr.34 - Controls, housing
Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
❑ Location: on transfer box ❑ Removing and installing ⇒ page 25 ❑ Location: on transfer box ❑ Removing and installing ⇒ page 15 ❑ Location: on transfer box ❑ Removing and installing ⇒ page 23
– 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- .
Install in reverse order of removal. During this step, observe the following: Transfer box control unit -J646- must engage in bracket.
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2. Electrical and electronic components and their locations for four-wheel drive
11
Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
♦ Torque wrench -V.A.G 1331-
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– Grease transfer box input shaft splines and gearbox output shaft splines with drive shaft grease -G 052 738 A2- . – Push transfer box completely onto gearbox, ensuring that transfer box input shaft splines are centred as they are guided onto the gearbox output shaft.
– Install front propshaft ⇒ page 59 . – Install rear propshaft ⇒ page 61 . – Check oil level in transfer box ⇒ page 14 .
Transfer box to gearbox
45 Nm
3. Removing and installing transfer box
13
Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
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♦ Oil level is below oil filler hole. ♦ Make a tool to check oil level.
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– Raise vehicle ⇒ Maintenance ; Booklet 11 . – Remove oil filler plug -1-. – Insert locally manufactured tool into filler hole downwards as far as possible. – Pull out tool and check oil level on tool. Top up oil if necessary. Gear oil level is correct if oil level is 32...37 mm below lower edge of filler hole. – Screw in new oil filler plug and tighten to 27 Nm.
– Remove oil filler plug -1-. – Fill 1.25 l of gear oil. – Screw in new oil filler plug and tighten to 27 Nm.
Rep. gr.34 - Controls, housing
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14
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V l o k s w a g e n A
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Amarok 2011 ➤ Transfer box and final drive - Edition 09.2010
❑ Removing ⇒ page 16 ❑ Driving in ⇒ page 16 ❑ For input shaft ❑ Always renew ❑ Insert in groove in input shaft ⇒ page 16 ❑ Qty. 2 ❑ For centring gearbox/ transfer box
❑ Renew if damaged ❑ On input shaft for front propshaft ❑ Renew y V d b
❑ On output shaft for front propshaft ❑ Renew if damaged
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❑ Removing and installing ⇒ page 23
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5. Assembly overview - transfer box
15
